Insulated concrete slip form and method of accelerating concrete curing using same

ABSTRACT

The invention comprises a concrete form. The form comprises a first concrete forming panel having a first primary surface adapted for forming and contacting plastic concrete and a second primary surface opposite the first primary surface; a layer of insulating material contacting and substantially covering the second primary surface of the first concrete forming panel; and an insulating blanket adjacent the first concrete forming panel. A method of using the concrete form is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of application Ser. No.14/480,948 filed Sep. 9, 2014, now U.S. Pat. No. 9,776,920, which claimsthe benefit of the filing date of U.S. provisional patent applicationSer. No. 61/875,167 filed Sep. 9, 2013.

FIELD OF THE INVENTION

The present invention generally relates to a form for cement-basedmaterials. More particularly, this invention relates to a concrete slipform, particularly an insulated concrete slip form. The presentinvention also relates to an electrically heated concrete slip form. Thepresent invention also relates to a method of curing concrete byretaining the heat of hydration. The present invention also relates to amethod for accelerating concrete curing using an insulated concrete slipform. The present invention also relates to a method of curing concretewith reduced amounts of portland cement, which produces a concrete thatcures faster and is stronger and more durable.

BACKGROUND OF THE INVENTION

Concrete is a composite material usually comprising a mineral-basedhydraulic binder which acts to adhere mineral particulates together in asolid mass; those particulates may consist of coarse aggregate (rock orgravel), fine aggregate (natural sand or crushed fines), and/orunhydrated or unreacted cementitious or pozzolanic material. Concretetypically is made from portland cement (“PC”), water and aggregate.Curing concrete requires two elements: suitable temperature and water.To achieve maximum strength, all cement particles must be hydrated. Theinitial process of hydration is exothermic; it generates a considerableamount of energy called the “heat of hydration.” Fluid (plastic)concrete is poured in various forms or molds. These prior artuninsulated forms are exposed to the environment, and, therefore, theenergy from the heat of hydration is generally lost to the environmentin the first 8-36 hrs. In the next few days, most of the free moistureis also lost from the concrete. Therefore, the two elements required tohydrate the cement are often lost during the initial stage of concretecuring. Thus, the cement may never fully hydrate, and, therefore, maynever achieve its maximum strength. Industry practice indicates thatportland cement concrete achieves 90% of its maximum strength underideal curing conditions in about 28 days.

Portland cement manufacture causes environmental impacts at all stagesof the process. During manufacture, a metric ton of CO₂ is released forevery metric ton of portland cement made. Worldwide CO₂ emissions fromportland cement manufacture amount to about 5%-7% of total CO₂emissions. The average energy input required to make one ton of portlandcement is about 4.7 million Btu—the equivalent of about 418 pounds ofcoal. The production of portland cement is therefore highly energyintensive, accounting for about 2% of primary energy consumptionglobally. In 2010 the world production of hydraulic cement was about3,300 million tons.

Concrete can also be made with slag cement (“SC”) and various otherpozzolans, such as fly ash (“FA”), but are not frequently used. Slagcement and fly ash generate relatively low amounts of heat of hydration,which result in extremely slow setting times and strength gain. Slagcement and fly ash can be mixed with portland cement but industrypractice in building construction limits use of slag cement and fly ashto no more than 30% replacement of portland cement and only during warmweather conditions. Concrete made with slag cement and fly ash may takeup to 90 days to achieve 80%-90% of maximum strength. Mass concretestructures use more slag cement and fly ash, replacing up to 80% ofportland cement, as a means to reduce the heat of hydration to reducecracking. Slag cement and fly ash use less water to hydrate, may havefiner particles than portland cement and produce concretes that achievehigher compressive and flexural strength. Such concrete is also lesspermeable, and, therefore, structures built with slag cement and fly ashhave far longer service lives or lifecycles.

Slag cement is obtained by quenching molten iron slag (a by-product ofiron and steel-making) from a blast furnace in water or steam, toproduce a glassy, granular product that is then dried and ground into afine powder. Slag cement manufacture uses only 15% of the energy neededto make portland cement. Since slag cement is made from waste materials;no virgin materials are required and the amount of landfill spaceotherwise used for disposal is reduced. For each metric ton of pig ironproduced, approximately ⅓ metric ton of slag is produced. In 2009,worldwide pig iron production was about 1.211 billion tons. There was anestimated 400 million tons of slag produced that could potentially bemade into slag cement. However, only a relatively small percentage ofslag is used to make slag cement in the USA.

Fly ash is a by-product of the combustion of pulverized coal in electricpower generation plants. When pulverized coal is ignited in a combustionchamber, the carbon and volatile materials are burned off. However, someof the mineral impurities of clay, shale, feldspars, etc. are fused insuspension and carried out of the combustion chamber in the exhaustgases. As the exhaust gases cool, the fused materials solidify intospherical glassy particles called fly ash. The quantity of fly ashproduced worldwide is growing along with the steady global increase incoal use. According to Obada Kayali, a civil engineer at the Universityof New South Wales Australian Defense Force Academy, only 9% of the 600million tons of fly ash produced worldwide in 2000 was recycled and evensmaller amount used in concrete; most of the rest is disposed of inlandfills. Since fly ash is a waste product, no additional energy isrequired to make it.

Concrete can also be made from a combination of portland cement andpozzolanic material or from pozzolanic material alone. There are anumber of pozzolans that historically have been used in concrete. Apozzolan is a siliceous or siliceous and aluminous material which, initself, possesses little or no cementitious value but which will, infinely divided form and in the presence of water, react chemically withcalcium hydroxide at ordinary temperatures to form compounds possessingcementitious properties (ASTM C618). The broad definition of a pozzolanimparts no bearing on the origin of the material, only on its capabilityof reacting with calcium hydroxide and water. The general definition ofa pozzolan embraces a large number of materials, which vary widely interms of origin, composition and properties. Both natural and artificial(man-made) materials show pozzolanic activity and are used assupplementary cementitious materials. Artificial pozzolans can beproduced deliberately, for instance by thermal activation ofkaolin-clays to obtain metakaolin, or can be obtained as waste orby-products from high-temperature process, such as fly ashes fromcoal-fired electricity production. The most commonly used pozzolanstoday are industrial by-products, such as slag cement (ground granulatedblast furnace slag), fly ash, silica fume from silicon smelting, highlyreactive metakaolin, and burned organic matter residues rich in silica,such as rice husk ash. Alternatives to the established pozzolanicby-products are to be found on the one hand in an expansion of the rangeof industrial by-products or societal waste considered and on the otherhand in an increased usage of naturally occurring pozzolans. Silica fume(also known as microsilica) is an amorphous form of silicon dioxide.Silica fume consists of sub-micron spherical primary particles.

Natural pozzolans are abundant in certain locations and are used as anaddition to portland cement in some countries. The great majority ofnatural pozzolans in use today are of volcanic origin. Volcanic ashesand pumices largely composed of volcanic glass are commonly used, as aredeposits in which the volcanic glass has been altered to zeolites byinteraction with alkaline waters. Deposits of sedimentary origin areless common. Diatomaceous earths, formed by the accumulation ofsiliceous diatom microskeletons, are a prominent source material here.Romans used volcanic ash mixed with lime to make concrete over 2,000years ago.

Concrete walls, and other concrete structures and objects, traditionallyare made by building a form or a mold. The forms and molds are usuallymade from wood, plywood, metal and other structural members. Unhardened(plastic) concrete is poured into the space defined by opposed spacedform members. Once the concrete hardens sufficiently, although notcompletely, the forms are removed leaving a concrete wall or otherconcrete structure, structural member or concrete object exposed toambient temperatures. Concrete forms are typically made of various typesof plywood or metal supported and/or reinforced by a frame structure.These forms are not insulated which means that concrete contained insuch forms is exposed to the elements during the curing process. Duringthe curing process, the heat generated by the hydration of cement islost to the environment. This often makes the curing of the concrete aslow process and the ultimate strength difficult to control or predict.To compensate for these losses and increase the rate of setting andstrength development, larger amounts of portland cement are used thanotherwise would be necessary.

The curing of plastic concrete requires two elements, water and heat, tofully hydrate the cementitious material. Cement hydration is anexothermic process. This heat is produced by the hydration of theportland cement, or other pozzolanic or cementitious materials, thatmake up the concrete paste. Initially, the hydration process produces arelatively large amount of heat. Concrete placed in conventional forms(i.e., uninsulated forms) loses this heat of hydration to theenvironment in a very short time, generally in the first 8-36 hours,depending on the ambient temperature. Also, concrete placed inconventional forms may not reach its maximum potential temperature. Asthe hydration process proceeds, relatively less heat of hydration isgenerated due to slowing reaction rates. At the same time, moisture inthe concrete is lost to the environment. If one monitors the temperatureof concrete during the curing process, it produces a relatively largeincrease in temperature, which then decreases relatively rapidly overtime. This chemical reaction is temperature dependent. That is, thehydration process, and consequently the strength gain, proceeds fasterat higher temperature and slower at lower temperature. In conventionalforms, both heat and moisture are lost in a relatively short time, whichmakes it difficult, or impossible, for the cementitious material tofully hydrate, and, therefore, the concrete may not achieve its maximumpotential strength.

Conventional forms or molds provide little or no insulation to theconcrete contained therein. Therefore, heat produced within the concreteform or mold due to the hydration process usually is lost through aconventional concrete form or mold relatively quickly. Thus, thetemperature of the plastic concrete may initially rise 20 to 40° C., ormore, above ambient temperature due to the initial hydration process andthen fall relatively quickly to ambient temperature, such as within 8 to36 hours depending on the climate and season and size of the concreteelement. This initial relatively large temperature drop may result insignificant concrete shrinkage and/or thermal effects which can lead toconcrete cracking. The remainder of the curing process is then conductedat approximately ambient temperatures, because the relatively smallamount of additional heat produced by the remaining hydration process isrelatively quickly lost through the uninsulated concrete form or mold.The concrete is therefore subjected to the hourly or daily fluctuationsof ambient temperature from hour-to-hour, from day-to-night and fromday-to-day. Failure to cure the concrete under ideal temperature andmoisture conditions affects the ultimate strength and durability of theconcrete. In colder weather, concrete work may even come to a halt sinceconcrete will freeze, or not gain much strength at all, at relativelylow temperatures. By definition (ACI 306), cold weather conditions existwhen “ . . . for more than 3 consecutive days, the average dailytemperature is less than 40 degrees Fahrenheit and the air temperatureis not greater than 50 degrees Fahrenheit for more than one-half of any24 hour period.” Therefore, in order for hydration to take place, thetemperature of concrete must be above 40° F.; below 40° F., thehydration process slows and at some point may stop altogether. Underconventional forming and curing methods, the concrete takes a relativelylong time to fully hydrate the cementitious materials. Since both theinitial heat and moisture are quickly lost in conventional forms, it istypically recommended that concrete by moisture cured for 28 days tofully hydrate the concrete. However, moisture curing for 28 days isseldom possible to administer in commercial practice. Therefore,concrete poured in various applications in conventional forms seldomdevelops it maximum potential strength and durability.

Insulated concrete form systems are known in the prior art and typicallyare made from a plurality of modular form members. U.S. Pat. Nos.5,497,592; 5,809,725; 6,668,503; 6,898,912 and 7,124,547 (thedisclosures of which are all incorporated herein by reference in theirentirety) are exemplary of prior art modular insulated concrete formsystems. Full-height insulated concrete forms are also known in theprior art. U.S. Patent Application Publication No. 2011/0239566 and2013/007432 (the disclosures of which are both incorporated herein byreference in their entirety) disclose full-height insulated concreteforms.

In accordance with the present invention, insulated concrete formsretain the heat of hydration and improve or accelerate concrete curingproperties. However, prior art insulated concrete forms are designed toremain in place on the concrete structure. Conventional removableconcrete forms are not insulated and therefore cannot retain the heat ofhydration.

Prior art concrete forms have not been proposed or used as a method tocure concrete or to improve the performance and properties of concrete.The present invention has discovered that when the initial heatgenerated by the hydration of cementitious material is retained in aninsulated concrete form, the concrete achieves a greater internaltemperature and such temperature is sustained for much longer periods oftime before it is lost to the environment. During this time, there issufficient moisture in the concrete to more fully hydrate thecementitious material.

In the construction of certain concrete structures, such as high-risebuildings, it is desirable to use a concrete slip form. Concrete slipforming is a construction method in which concrete is poured into acontinuously moving form. Slip forming is typically used for relativelytall structures, such as bridges, towers, high-rise buildings, silos,grain elevators and the like, as well as horizontal structures, such asaircraft runways and automotive highways. Slip forming enablescontinuous, uninterrupted, cast-in-place concrete structures, usuallywithout joints, which thereby provides the concrete with superiorperformance characteristics relative to construction using discrete formelements. Slip forming relies on the relatively quick-setting propertiesof concrete, and requires a careful balance between quick-settingcapability and concrete workability. Concrete needs to be sufficientlyworkable to be placed into a form and, if necessary, consolidated, suchas by vibration. On the other hand, in slip forming concrete must besufficiently quick-setting to emerge from the moving form withsufficient strength to support its own weight. Such strength isnecessary because the freshly set concrete must not only permit the formto “slip,” but in vertical applications, the slip formed concrete mustalso support the weight of freshly poured concrete above it.

Due to the quick-setting properties required for slip forming concrete,concrete mixes employing reduced amounts of portland cement andrelatively large amounts of supplementary cementitious or pozzolanicmaterials are not used for slip forming processes.

SUMMARY OF THE INVENTION

The present invention satisfies the foregoing needs by providing animproved concrete slip forming system to retain the heat of hydration ofcuring concrete.

In one disclosed embodiment, the present invention comprises a concreteform. The form comprises a first concrete forming panel having a firstprimary surface adapted for forming and contacting plastic concrete anda second primary surface opposite the first primary surface; a layer ofinsulating material contacting and substantially covering the secondprimary surface of the first concrete forming panel; and an insulatingblanket adjacent the first concrete forming panel.

In another disclosed embodiment, the present invention comprises amethod. The method comprises placing a first quantity of plasticconcrete in a concrete form, wherein the concrete form comprises: afirst concrete forming panel having a first primary surface adapted forforming and contacting plastic concrete and a second primary surfaceopposite the first primary surface; and a layer of insulating materialcontacting and substantially covering the second primary surface of thefirst concrete forming panel. The method also comprises moving theconcrete form to an adjacent position, wherein at least a portion of thefirst quantity of plastic concrete is not within the concrete form. Themethod further comprises placing a second quantity of plastic concretein the concrete form and substantially covering the portion of the firstquantity of plastic concrete not within the concrete form with aninsulating blanket.

In another disclosed embodiment, the present invention comprises amethod. The method comprises selectively adding heat to a first quantityof concrete so that the first quantity of concrete follows a firstpredetermined temperature profile. The method also comprises selectivelyadding heat to a second quantity of concrete adjacent to the firstquantity of concrete so that the second quantity of concrete follows asecond predetermined temperature profile different from the firstpredetermined temperature profile

Therefore, it is an object of the present invention to provide animproved insulated concrete slip form.

Another object of the present invention is to provide an insulatedconcrete slip form that can be used in the same manner as conventionalprior art concrete slip forms.

A further object of the present invention is to provide a method ofcuring concrete by retaining the heat of hydration within the concretethereby accelerating the hydration and curing of cementitious materialsto achieve concrete with improved properties.

Another object of the present invention is to provide an improved methodfor curing concrete by more fully hydrating the cementitious materialbefore needed heat and moisture are lost to the environment.

Another object of the present invention is to provide a system forcuring concrete such that the concrete develops its maximum strength asearly as possible.

A further object of the present invention is to provide a concretecuring system that uses reduced amounts of portland cement whileproducing concrete having an ultimate strength equivalent to concretemade with conventional amounts of portland cement.

Another object of the present invention is to provide a concrete curingsystem that substantially reduces the use of portland cement whileproducing concrete having an ultimate strength equivalent to concretemade with conventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses relatively large amounts of recycled industrialwaste material, such as slag cement, fly ash, silica fume, pulverizedglass and/or rice husk ash, while producing concrete having an ultimatestrength equivalent to, or better than, concrete made with conventionalamounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses inert or filler material, such as groundlimestone, calcium carbonate, titanium dioxide, or quartz, whileproducing concrete having an ultimate strength equivalent to, or betterthan, concrete made with conventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses relatively large amounts of recycled industrialwaste material, such as slag cement, fly ash, silica fume, pulverizedglass and/or rice husk ash, in combination with inert or fillermaterial, such as ground limestone, calcium carbonate, titanium dioxide,or quartz, while producing concrete having an ultimate strengthequivalent to, or better than, concrete made with conventional amountsof portland cement.

Another object of the present invention is to provide a system forcuring concrete such that concrete mixes containing reduced amounts ofportland cement can be cured efficiently and effectively therein whilehaving compressive strengths equivalent to, or better than, conventionalconcrete mixes.

A further object of the present invention is to provide a concretecuring system that uses pozzolanic materials as a partial, or full,replacement for portland cement, while producing concrete having anultimate strength equivalent to, or better than, concrete made withconventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses artificial pozzolans, such as fly ash,metakaolin, rice husk ash and silica fume, as a partial, or full,replacement for portland cement, while producing concrete having anultimate strength equivalent to, or better than, concrete made withconventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses natural pozzolans, such as volcanic ash similarto the Roman concrete, as a partial, or full, replacement for portlandcement, while producing concrete having an ultimate strength equivalentto, or better than, concrete made with conventional amounts of portlandcement.

Yet another object of the present invention is to provide a system forcuring concrete such that the concrete develops its maximum durability.

Another object of the present invention is to provide a system forcuring concrete more quickly.

Another object of the present invention is to provide an improvedconcrete slip form.

Another object of the present invention is to provide an insulatedconcrete slip form that provides insulation for conductive heat loss.

Another object of the present invention is to provide an insulatedconcrete slip form that provides insulation for radiant heat loss.

A further object of the present invention is to provide an electricallyheated concrete slip form.

Another object of the present invention is to provide heat to concreteas it is being slip formed.

Another object of the present invention it is provide heat to concreteas it is being slip formed so that the temperature of the concretefollows a predetermined temperature profile.

Another object of the present invention is to provide insulation to slipformed concrete after the concrete slip form has moved (e.g., raised forthe addition of additional concrete to the slip form) so as to retainthe heat of hydration.

Another object of the present invention is to provide heat to slipformed concrete after the concrete slip form has moved (e.g., raised forthe addition of additional concrete to the slip form) so as to maintainthe concrete at a desired temperature.

Yet another object of the present invention is to provide heat to slipformed concrete after the concrete slip form has moved (e.g., raised forthe addition of additional concrete to the slip form) so that thetemperature of the concrete follows a predetermined temperature profile.

These and other objects, features and advantages of the presentinvention will become apparent after a review of the following detaileddescription of the disclosed embodiments and the appended drawing andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially broken away perspective view of a disclosedembodiment of an insulated concrete slip form in accordance with thepresent invention.

FIG. 2 is a partially broken away cross-sectional view taken along theline 2-2 of the insulated concrete slip form shown in FIG. 1.

FIG. 3 is a cross-sectional view taken along the line 3-3 of theinsulated concrete slip form shown in FIG. 1.

FIG. 4 is a partially broken away perspective view of a disclosedembodiment of an insulated concrete slip form assembly in accordancewith the present invention for forming a concrete column.

FIG. 5 is a partially broken away cross-sectional view taken along theline 5-5 of the insulated concrete slip form assembly shown in FIG. 4.

FIG. 6 is a partially broken away cross-sectional view taken along theline 6-6 of the insulated concrete slip form assembly shown in FIG. 5.

FIG. 7 is a partially broken away cross-sectional view taken along theline 7-7 of the insulated concrete slip form assembly shown in FIG. 5.

FIG. 8 is a partially broken away perspective view of an electricallyheated concrete forming panel for use with a concrete slip form inaccordance with the present invention.

FIG. 9 is a partially broken away side view of the electrically heatedconcrete forming panel shown in FIG. 8.

FIG. 10 is a cross-sectional view taken along the line 10-10 of theelectrically heated concrete forming panel shown in FIG. 8.

FIG. 11 is a partially broken away perspective view of an electricallyheated concrete slip form in accordance with the present invention.

FIG. 12 is a partially broken away front view of the electrically heatedconcrete slip form shown in FIG. 11.

FIG. 13 is a cross-sectional view taken along the line 13-13 of theelectrically heated concrete slip form shown in FIG. 12.

FIG. 14 is a cross-sectional view taken along the line 14-14 of theelectrically heated concrete slip form shown in FIG. 13.

FIG. 15 is a schematic view of a disclosed embodiment of an electricallyheated concrete slip form assembly in accordance with the presentinvention.

FIG. 16 is a flow diagram of a disclosed embodiment of a temperaturecontrolled concrete curing process utilizing an electrically heatedconcrete slip form assembly in accordance with the present invention.

FIG. 17 is a graph of concrete temperature versus elapsed concretecuring time of a disclosed embodiment of a curing temperature profilefor concrete in accordance with the present invention. An example ofambient temperature is also shown on the graph.

FIG. 18 is a flow diagram of another disclosed embodiment of atemperature controlled concrete curing process utilizing an electricallyheated concrete slip form assembly in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

Referring now to the drawing in which like numbers indicate likeelements throughout the several views, there is shown in FIG. 1 adisclosed embodiment of an insulated concrete slip form 10 in accordancewith the present invention. The insulated concrete slip form 10comprises a rectangular concrete forming face or first panel 12 made ofany suitable material typically used in prior art concrete forms or anyother materials that are sufficiently strong to withstand thehydrostatic pressure of plastic concrete applied to it. The concreteforming first panel 12 can be made from any suitable material including,but not limited to, wood, plywood, high density overlay (HDO) plywood,wood composite materials, wood or composite materials with polymercoatings, plastic, plastic composites, and metal, such as steel oraluminum. The concrete forming first panel is preferably made from aconductive heat insulating material or a poor heat conducting material.A preferred material for the first panel 12 is a sheet of high densityoverlay (HDO) plywood. The first panel 12 can be any useful thicknessdepending on the anticipated loads to which the form will be subjected.However, plywood thicknesses of ⅛ inch to ⅞ inches can be used. Thefirst panel 12 has a first primary surface 14 for contacting plasticconcrete and an opposite second primary surface 16. The first primarysurface 14 is usually smooth and flat. The first primary surface 14 canalso include a polymer coating to make the surface smoother, moredurable and/or provide better release properties. The first primarysurface 14 of the concrete forming first panel 12 contacts concrete thatis placed between a pair of opposed insulated concrete slip form 10 inaccordance with the present invention. The first panel 12 defines aplane. Optionally, but preferably, there is a second panel 18 that isthe same size as the first panel 12. The second panel 18 can be madefrom the same material as the first panel 12, or it can be made from adifferent material. The second panel 18 has a first primary surface 20and an opposite second primary surface 22.

The first panel 12 and/or the second panel 18 are attached directly orindirectly to a frame 24 by any means known in the art. The rectangularframe 24 comprises two elongate longitudinal members 26, 28 and twoelongate transverse members 30, 32. The longitudinal members 26, 28 andthe transverse members 30, 32 are attached to each other and to thefirst panel 12 and/or the second panel 18 by any suitable means used inthe prior art. The frame 24 also comprises at least one, and preferablya plurality, of transverse bracing members 34, 36, 38, 40, 42, 44, 46,48, 50. The transverse bracing members 34-50 are attached to thelongitudinal members 26, 28 and optionally to the first panel 12 and/orthe second panel 18 by any suitable means used in the prior art. Theframe 24 also includes bracing members 52, 54 and 56 (a fourth bracingmember is not shown). The bracing members 52, 54 extend between thetransverse member 26 and the bracing member 28. The bracing members 52,54 are attached to the transverse member 30 and the bracing member 34 byany suitable means used in the prior art. The bracing member 56 (and abracing member not shown) extends between the transverse member 32 andthe bracing member 50. The bracing member 56 is attached to thetransverse member 32 and the bracing member 50 by any suitable meansused in the prior art. The frame 24 helps prevent the first and secondpanels 12, 18 from flexing or deforming under the hydrostatic pressureof plastic concrete when placed between two opposed insulated concreteslip forms 10. Therefore, the frame 24 must be made in such a way so asto withstand the anticipated hydrostatic pressure to which the frame 24will be subjected. The frame 24 can be made from any suitable materialused in the prior art including, but not limited to, wood or metal, suchas aluminum or steel, depending on the load to which the insulatedconcrete slip form 10 will be subjected. The particular design of theframe 24 is not critical to the present invention. There are manydifferent sizes, shapes and designs of frames for concrete slip formsand they are all applicable to the present invention. Preferably, noportion of the frame 24 is in the plane defined by the first panel 12.Preferably there is no substantial thermal bridging between the firstpanel 12 and the second panel 18. Preferably there is no substantialthermal bridging between the first panel 12 and the frame 24. As usedherein the term “thermal bridging” means direct contact with a materialhaving heat conducting properties equivalent to metal, such as steel oraluminum. As used herein the term “no substantial thermal bridging”means no more thermal bridging than would be associated with attachingthe first panel 12 to the second panel 14 and/or attaching the firstpanel to the frame 24, such as by screws or nails or similar connectors.

The present invention departs from conventional prior art concrete slipforms, as explained below. Disposed between the first panel 12 andsecond panel 18 is a layer of insulating material 60. The layer ofinsulating material 60 covers, or substantially covers, the secondprimary surface 16 of the first panel 12 and the first primary surface20 of the second panel 18. As used herein the term “substantiallycovers” means covering at least 80% of the primary surface area of thefirst and/or second panels 12, 18. The layer of insulating material 60is made from any suitable material providing heat insulating properties,preferably a sheet of closed cell polymeric foam. The layer ofinsulating material 60 is preferably made from closed cell foamsincluding, but not limited to, polyvinyl chloride, urethane,polyurethane, polyisocyanurate, phenol, polyethylene, polyimide orpolystyrene. Such polymeric foam sheet preferably has a density of 1 to3 pounds per cubic foot, or more. The layer of insulating material 60preferably has insulating properties equivalent to at least 0.25 inchesof expanded polystyrene foam, preferably equivalent to at least 0.5inches of expanded polystyrene foam, preferably equivalent to at least 1inch of expanded polystyrene foam, more preferably equivalent to atleast 2 inches of expanded polystyrene foam, more preferably equivalentto at least 3 inches of expanded polystyrene foam, most preferablyequivalent to at least 4 inches of expanded polystyrene foam, especiallyequivalent to at least 8 inches of expanded polystyrene foam. There isno maximum thickness for the layer of insulting material equivalent toexpanded polystyrene foam useful in the present invention. The maximumthickness is usually dictated by economics, weight, ease of handling andbuilding or structure design. However, for most applications a maximuminsulating equivalence of 8 inches of expanded polystyrene foam can beused. In another embodiment of the present invention, the layer ofinsulating material 60 has insulating properties equivalent toapproximately 0.25 to approximately 8 inches of expanded polystyrenefoam, preferably approximately 0.5 to approximately 8 inches of expandedpolystyrene foam, preferably approximately 1 to approximately 8 inchesof expanded polystyrene foam, preferably approximately 2 toapproximately 8 inches of expanded polystyrene foam, more preferablyapproximately 3 to approximately 8 inches of expanded polystyrene foam,most preferably approximately 4 to approximately 8 inches of expandedpolystyrene foam. These ranges for the equivalent insulating propertiesfor the layer of insulating material 60 include all of the intermediatevalues. Thus, the layer of insulating material 60 used in anotherdisclosed embodiment of the present invention has insulating propertiesequivalent to approximately 0.25 inches of expanded polystyrene foam,approximately 0.5 inches of expanded polystyrene foam, approximately 1inch of expanded polystyrene foam, approximately 2 inches of expandedpolystyrene foam, approximately 3 inches of expanded polystyrene foam,approximately 4 inches of expanded polystyrene foam, approximately 5inches of expanded polystyrene foam, approximately 6 inches of expandedpolystyrene foam, approximately 7 inches of expanded polystyrene foam,or approximately 8 inches of expanded polystyrene foam. Expandedpolystyrene foam has an R-value of approximately 4 to 6 per inchthickness. Therefore, the layer of insulating material 60 should have anR-value of greater than 1.5, preferably greater than 4, more preferablygreater than 8, most preferably greater than 12, especially greater than20, more especially greater than 30, most especially greater than 40.The layer of insulating material 60 preferably has an R-value ofapproximately 1.5 to approximately 40; more preferably betweenapproximately 4 to approximately 40; especially approximately 8 toapproximately 40; more especially approximately 12 to approximately 40.The layer of insulating material 60 preferably has an R-value ofapproximately 1.5, more preferably approximately 4, most preferablyapproximately 8, especially approximately 20, more especiallyapproximately 30, most especially approximately 40.

The layer of insulating material 60 can also be made from a refractoryinsulating material, such as a refractory blanket, a refractory board ora refractory felt or paper. Refractory insulation is typically used toline high temperature furnaces or to insulate high temperature pipes.Refractory insulating material is typically made from ceramic fibersmade from materials including, but not limited to, silica, siliconcarbide, alumina, aluminum silicate, aluminum oxide, zirconia, calciumsilicate; glass fibers, mineral wool fibers, Wollastonite and fireclay.Refractory insulating material is commercially available in variousforms including, but not limited to, bulk fiber, foam, blanket, board,felt and paper form. Refractory insulation is commercially available inblanket form as Fiberfrax Durablanket® insulation blanket from Unifrax ILLC, Niagara Falls, N.Y., USA and RSI4-Blank and RSI8-Blank fromRefractory Specialties Incorporated, Sebring, Ohio, USA. Refractoryinsulation is commercially available in board form as Duraboard® fromUnifrax I LLC, Niagara Falls, N.Y., USA and CS85, Marinite and Transiteboards from BNZ Materials Inc., Littleton, Colo., USA. Refractoryinsulation in felt form is commercially available as Fibrax Felts andFibrax Papers from Unifrax I LLC, Niagara Falls. The refractoryinsulating material can be any thickness that provides the desiredinsulating properties, as set forth above. There is no upper limit tothe thickness of the refractory insulating material; this is usuallydictated by economics and weight. However, refractory insulatingmaterial useful in the present invention can range from 1/32 inch toapproximately 2 inches. Similarly, ceramic fiber materials including,but not limited to, silica, silicon carbide, alumina, aluminum silicate,aluminum oxide, zirconia, calcium silicate; glass fibers, mineral woolfibers, Wollastonite and fireclay, can be suspended in a polymer, suchas polyurethane, latex, cement or epoxy, and used as a coating or apolymeric foam to create a refractory insulating material layer, forexample covering, or substantially covering, one of the primary surfaces16, 20 of the first or second panels 12, 18, or both. Such a refractoryinsulating material layer can be used as the layer of insulatingmaterial 60 to block excessive ambient heat loads and retain the heat ofhydration of concrete within the insulated concrete slip forms 10 of thepresent invention. Ceramic fibers suspended in a polymer binder, such aslatex, are commercially available as Super Therm®, Epoxotherm and HPCCoating from Superior Products, II, Inc., Weston, Fla., USA.

The layer of insulating material 60 is preferably a multi-layer materialwith a first layer of refractory insulating material and a second layerof closed cell polymeric foam insulating material. The layer ofinsulating material 60 more preferably comprises a layer of ceramicfibers suspended in a polymer, especially a polymeric foam including,but not limited to, polystyrene foam, polyurethane foam,polyisocyanurate foam, latex foam or any other suitable type ofpolymeric foam.

The first and second panels 12, 18 are preferably made from rigid sheetsof wood, plywood, metal, plastic, fibers or composite materials. Thefirst and second panels 12, 18 are preferably made from the samematerial. However, it is also contemplated that one of the first andsecond panels 12, 18 can be made from one of wood, plywood, metal,plastic, fibers or composite materials and the other made from adifferent one of wood, plywood, metal, plastic, fibers or compositematerials. Suitable metals include, but are not limited to, steel andaluminum. Suitable plastics include, but are not limited to,polyethylene (PE), poly(ethylene terephthalate) (PET), polypropylene(PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC),acrylonitrile butadiene styrene (ABS), polycarbonate, polystyrene,nylon, urethane, polyurethane (PU), polyisocyanurate, phenol, polyimide,acrylic polymers such as polyacrylate, poly(methyl methacrylate) (PMMA),and the like. Fiberboard is a type of engineered wood product that ismade out of wood fibers. Composite materials include fiberglass board,which is a laminated product of glass and epoxy resin and otherlaminates. Fiberglass boards are commercially available from OwensCorning, Monsey, N.Y.; Current, Inc., East Have, Conn. and under thedesignation Exact-O-Board from Pacor, Inc., Bordentown, N.J. Othercomposite laminates include laminated products comprised of layers ofcloth or paper with thermosetting resins cured under elevated pressureand temperature.

A particularly preferred plastic sheet for use as the first and/orsecond panels 12, 18 is corrugated plastic. Corrugated plastic sheettypically comprises two planar plastic sheets spaced from each other butconnected to each other by a plurality of small I-beam formed plasticconnections. The I-beam formed plastic connections between the planarsheets of plastic can be either perpendicular to the planar sheets ofplastic or slanted. Corrugated plastic sheets can also be made bysandwiching a fluted sheet of plastic between two flat sheets of plastic(also called facings). The sheets can be joined together by gluing. Thecorrugated plastic sheet can be single wall corrugated sheets, doublewall corrugated sheets or triple wall corrugated sheets. The layer ofinsulating material 60 can then be applied to one or both of thecorrugated sheets that form the first and second panels 12, 18 or thelayer of insulating material can be adhered to one or both of thecorrugated sheets.

It is typical for wood or wood composite panels used for concreteforming panels to include a polymer coating on the surface that contactsthe concrete. This provides better concrete release properties to thepanel. It is a part of the present invention that a polymer coating isoptionally applied to the first primary surface 14 of the concreteforming first panel 12 and that the polymer coating includes heatinsulating materials, such as refractory insulating materials.Refractory insulating material is typically made from ceramic fibersmade from materials including, but not limited to, silica, siliconcarbide, alumina, aluminum silicate, aluminum oxide, zirconia, calciumsilicate; glass fibers, mineral wool fibers, Wollastonite and fireclay.It is a part of the present invention that a polymer coating isoptionally applied to the first primary surface 14 of the concreteforming first panel 12 and that the polymer coating includes heatreflective materials. Heat reflective materials are made from materialsincluding, but not limited to, mica, aluminum flakes, magnetite,graphite, carbon, other types of silicates and combinations thereof. Theabove heat reflective materials can be used in any number ways andcombination percentages, not just as a single element added to thepolymeric material. The heat reflective elements can also be used inconjunction with the ceramic fibers mentioned above in any number ofways and percentage combinations. The heat insulating materials and/orthe heat reflective materials can be added to the polymeric materialused to coat the first primary surface 14 of the concrete forming firstpanel 12 in amounts of approximately 0.1% to approximately 50% by weightheat reflective elements, preferably approximately 0.1% to approximately40% by weight, more preferably approximately 0.1% to approximately 30%by weight, most preferably approximately 0.1% to approximately 20% byweight, especially approximately 0.1% to approximately 15% by weight,more especially approximately 0.1% to approximately 10% by weight, mostespecially approximately 0.1% to approximately 5% by weight. Thepolymeric material used to coating the first primary surface 14 of theconcrete forming first panel 12 includes, but is not limited to,polyethylene (PE), poly(ethylene terephthalate) (PET), polypropylene(PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC),acrylonitrile butadiene styrene (ABS), polycarbonate, polystyrene,nylon, urethane, polyurethane (PU), polyisocyanurate, phenol, polyimide,acrylic polymers such as polyacrylate, poly(methyl methacrylate) (PMMA),latex polymers, epoxy resin and the like.

In another disclosed embodiment, if the corrugations of a corrugatedplastic sheet are large enough; e.g., approximately 0.5 inches betweenthe facings, the two facings of the corrugated sheet can be use as thefirst and second panels 12, 18. The layer of insulating material 60 thenpreferably can be injected between the two facings and between thecorrugations. In this case, the layer of insulating material 60 ispreferably foamed liquid plastic or a liquid plastic that blows in situto form a foam. The foamed liquid plastic or a liquid plastic that blowsin situ is then allowed to set and cure inside the corrugated plasticsheet. A corrugated metal sheet can also be used in the presentinvention and made in the same manner as the corrugated plastic sheet,as described above.

In another disclosed embodiment a first plastic sheet can be laid on awork surface. A layer of plastic foam, or a layer of liquid plastic thatblows in situ, can then be deposited on the first plastic sheet. Asecond plastic sheet can then be disposed on the layer of plastic foamor the layer of liquid plastic that blows in situ. After the layer ofplastic foam, or the layer of liquid plastic that blows in situ, isdeposited between the first and second plastic sheets, or after thelayer of liquid plastic blows in situ has blown (i.e., expanded), thefirst and second plastic sheets can be gauged to a desired thickness,such as by passing the first and second plastic sheets between a pair ofspaced gauge rollers. After the first and second plastic sheets havebeen gauged to a desired thickness, the layer of plastic foam or thelayer of liquid plastic that blows in situ is allowed to cure. Ifnecessary, the sandwich of the first and second plastic sheets with thelayer of plastic foam in between can be cut to a desired size and/orshape.

In another disclosed embodiment a first metal sheet can be laid on awork surface. A layer of plastic foam, or a layer of liquid plastic thatblows in situ, can then be deposited on the first metal sheet. A secondmetal sheet can then be disposed on the layer of plastic foam, or alayer of liquid plastic that blows in situ after the liquid plastic isblown (i.e., expanded). Before the layer of plastic foam, or the blownlayer of liquid plastic, sets up, the first and second metal sheets canbe gauged to a desired thickness, such as by passing the first andsecond metal sheets between a pair of spaced gauge rollers. After thefirst and second metal sheets have been gauged to a desired thickness,the layer of plastic foam, or the blown layer of liquid plastic, isallowed to cure. If necessary, the sandwich of the first and secondmetal sheets with the layer of plastic foam in between can be cut to adesired size and/or shape. Any of the foregoing plastic foams can haveceramic fibers suspended therein, so as to provide an efficientconductive heat insulating and radiant heat reflective material.

Optionally, the layer of insulating material 60 can include a layer ofradiant heat reflective material. The layer of radiant heat reflectivematerial can be made from any suitable material that reflects radiantheat, such as metal foil, especially aluminum foil, or a metalizedpolymeric film, more preferably, metalized biaxially-orientedpolyethylene terephthalate film, especially aluminizedbiaxially-oriented polyethylene terephthalate film. Biaxially-orientedpolyethylene terephthalate film is commercially available under thedesignation Mylar®, Melinex® and Hostaphen®. Mylar® film is typicallyavailable in thicknesses of approximately 1 mil or 2 mil. AluminizedMylar® film is commercially available from the Cryospares division ofOxford Instruments Nanotechnology Tools Ltd., Abingdon, Oxfordshire,United Kingdom and from New England Hydroponics, Southampton, Mass.,USA.

Use of the insulated concrete slip form 10 will now be considered. Aparticular advantage of the present invention is that the insulatedconcrete slip form 10 can be used in the same manner as a conventionalprior art concrete slip form. As shown in FIGS. 4-7, two insulatedconcrete slip forms 100, 102 identical to the insulated concrete slipform 10 are placed vertically and horizontally spaced from each other,in a manner well known in the art. Two additional insulated concreteslip forms 104, 106 identical to the insulated concrete slip form 10 areplaced vertically and horizontally spaced from each other, in a mannerwell known in the art. In the present embodiment, the concrete slipforms 100-106 are attached to each other and are arranged to form asquare concrete column or pier. However, the insulated concrete slipform 10 of the present invention can be sized, shaped and arranged withother insulated concrete slip forms in accordance with the presentinvention to form a concrete slip form of any desired size, shape ordesign. It is specifically contemplated that the insulated concrete slipform 10 in accordance with the present invention can be used to formcolumns, walls, piers and the like.

After the insulated concrete slip forms 100-106 are erected in thedesired configuration, plastic concrete is placed in the space definedby the four opposed insulated concrete slip forms (FIGS. 4-7).Optionally, but preferably, after the plastic concrete is placed in theinsulated concrete slip forms 100-106, a layer of insulating material108 is placed on top of the four insulated concrete slip forms and overthe plastic concrete contained therein, as shown in FIG. 4. The layer ofinsulating material 108 is made from any suitable material providingconductive heat insulating properties, preferably a sheet of closed cellpolymeric foam. The layer of insulating material 108 is preferably madefrom closed cell foams including, but not limited to, polyvinylchloride, urethane, polyurethane, polyisocyanurate, phenol,polyethylene, polyimide or polystyrene. Such foam preferably has adensity of 1 to 3 pounds per cubic foot, or more. The layer ofinsulating material 108 preferably has insulating properties equivalentto at least 0.25 inches of expanded polystyrene foam, preferablyequivalent to at least 0.5 inches of expanded polystyrene foam,preferably equivalent to at least 1 inch of expanded polystyrene foam,more preferably equivalent to at least 2 inches of expanded polystyrenefoam, more preferably equivalent to at least 3 inches of expandedpolystyrene foam, most preferably equivalent to at least 4 inches ofexpanded polystyrene foam, especially equivalent to at least 8 inches ofexpanded polystyrene foam. There is no maximum thickness for the layerof insulting material 108 equivalent to expanded polystyrene foam usefulin the present invention. The maximum thickness is usually dictated byeconomics, weight, ease of handling and building or structure design.However, for most applications a maximum insulating equivalence of 8inches of expanded polystyrene foam can be used. In another embodimentof the present invention, the layer of insulating material 108 hasinsulating properties equivalent to approximately 0.25 to approximately8 inches of expanded polystyrene foam, preferably approximately 0.5 toapproximately 8 inches of expanded polystyrene foam, preferablyapproximately 1 to approximately 8 inches of expanded polystyrene foam,preferably approximately 2 to approximately 8 inches of expandedpolystyrene foam, more preferably approximately 3 to approximately 8inches of expanded polystyrene foam, most preferably approximately 4 toapproximately 8 inches of expanded polystyrene foam. These ranges forthe equivalent insulating properties for the layer of insulatingmaterial 108 include all of the intermediate values. Thus, the layer ofinsulating material 108 used in another disclosed embodiment of thepresent invention has insulating properties equivalent to approximately0.25 inches of expanded polystyrene foam, approximately 0.5 inches ofexpanded polystyrene foam, approximately 1 inch of expanded polystyrenefoam, approximately 2 inches of expanded polystyrene foam, approximately3 inches of expanded polystyrene foam, approximately 4 inches ofexpanded polystyrene foam, approximately 5 inches of expandedpolystyrene foam, approximately 6 inches of expanded polystyrene foam,approximately 7 inches of expanded polystyrene foam, or approximately 8inches of expanded polystyrene foam. Expanded polystyrene foam has anR-value of approximately 4 to 6 per inch thickness. Therefore, the layerof insulating material 108 should have an R-value of greater than 1.5,preferably greater than 4, more preferably greater than 8, mostpreferably greater than 12, especially greater than 20, more especiallygreater than 30, most especially greater than 40. The layer ofinsulating material 108 preferably has an R-value of approximately 1.5to approximately 40; more preferably between approximately 4 toapproximately 40; especially approximately 8 to approximately 40; moreespecially approximately 12 to approximately 40. The layer of insulatingmaterial 108 preferably has an R-value of approximately 1.5, morepreferably approximately 4, most preferably approximately 8, especiallyapproximately 20, more especially approximately 30, most especiallyapproximately 40.

The layer of insulating material 108 can also be made from a refractoryinsulating material, such as a refractory blanket, a refractory board ora refractory felt or paper. Refractory insulation is typically used toline high temperature furnaces or to insulate high temperature pipes.Refractory insulating material is typically made from ceramic fibersmade from materials including, but not limited to, silica, siliconcarbide, alumina, aluminum silicate, aluminum oxide, zirconia, calciumsilicate; glass fibers, mineral wool fibers, Wollastonite and fireclay.Refractory insulating material is commercially available in variousforms including, but not limited to, bulk fiber, foam, blanket, board,felt and paper form. Refractory insulation is commercially available inblanket form as Fiberfrax Durablanket® insulation blanket from Unifrax ILLC, Niagara Falls, N.Y., USA and RSI4-Blank and RSI8-Blank fromRefractory Specialties Incorporated, Sebring, Ohio, USA. Refractoryinsulation is commercially available in board form as Duraboard® fromUnifrax I LLC, Niagara Falls, N.Y., USA and CS85, Marinite and Transiteboards from BNZ Materials Inc., Littleton, Colo., USA. Refractoryinsulation in felt form is commercially available as Fibrax Felts andFibrax Papers from Unifrax I LLC, Niagara Falls. The refractoryinsulating material can be any thickness that provides the desiredinsulating properties, as set forth above. There is no upper limit onthe thickness of the refractory insulating material; this is usuallydictated by economics. However, refractory insulating material useful inthe present invention can range from 1/32 inch to approximately 2inches. Similarly, ceramic fiber materials including, but not limitedto, silica, silicon carbide, alumina, aluminum silicate, aluminum oxide,zirconia, calcium silicate; glass fibers, mineral wool fibers,Wollastonite and fireclay, can be suspended in a polymer, such aspolyurethane, latex, cement or epoxy, and used as a coating or apolymeric foam to create a refractory insulating material layer. Such arefractory insulating material layer can be used as the layer ofinsulating material 108 to block excessive ambient heat loads and retainthe heat of hydration of concrete within the insulated concrete slipforms of the present invention. Ceramic fibers suspended in a polymerbinder, such as latex, are commercially available as Super Therm®,Epoxotherm and HPC Coating from Superior Products, II, Inc., Weston,Fla., USA.

The layer of insulating material 108 is preferably a multi-layermaterial with a first layer of refractory insulating material and asecond layer of polymeric foam insulating material. The layer ofinsulating material 108 more preferably comprises a layer of ceramicfibers suspended in polymeric foam and a layer of expanded polystyrenefoam. The layer of insulating material 108 optionally can include alayer of radiant heat reflecting material, such as a layer of polymericfoam with a radiant heat reflective metal foil, such as aluminum foil,laminated to one primary surface thereof.

The layer of insulating material 108 is preferably a concrete insulatingblanket having the insulating properties described above. Concreteinsulating blankets, are commercially available under the designationconcrete insulating blankets from Pregis Corp., Lake Forest, Ill. andconcrete curing blankets from Granite City Tool, Waite Park, Minn.Alternatively, the layer of insulating material 108 is an electricallyheated blanket. Such electrically heated insulating blankets have beenused in highway construction in the northern United States to preventplastic concrete from freezing in winter weather. Suitable electricallyheated insulating blankets are commercially available under thedesignation Powerblanket from Power Blanket LLC, Salt Lake City, Utah.

The insulated concrete slip forms 100-106 and layer of insulatingmaterial 108 are left in place for a time sufficient for the plasticconcrete within the forms to at least partially cure. While theinsulated concrete slip forms 100-106 and the layer of insulatingmaterial 108 are in place, the layer of insulating material 60 and thelayer of insulating material 108 retain at least a portion, preferably amajor portion, of the heat of hydration from the curing concrete withinthe insulated concrete slip forms. By retaining at least a portion ofthe heat of hydration, the plastic concrete in the insulated concreteslip forms 100-106 cures more quickly and achieves better physicalproperties than it would have had it been cured in a conventionalconcrete slip form; i.e., a non-insulated concrete slip form. This istrue for conventional portland cement concrete, but even more so forconcrete including significant amounts of supplementary cementitiousmaterial, such as slag cement and/or fly ash, or other pozzolans, asdescribed below. Furthermore, it is desirable to leave the insulatedconcrete slip forms 100-106 and the layer of insulating material 108 inplace with the curing concrete therein for a period of approximately 3hours to approximately 7 days, preferably approximately 3 hours toapproximately 3 days, preferably approximately 6 hours to approximately3 days, more preferably approximately 12 hours to approximately 3 days,especially approximately 12 hours to approximately 2 days, moreespecially approximately 12 hours to approximately 24 hours, mostespecially approximately 1 hour to 24 hours. After the concrete hascured to a desired degree, the insulated concrete slip forms 100-106 aremoved upwardly in a conventional manner known in the art. The insulatedconcrete slip forms of the present invention, such as the insulatedconcrete slip forms 100-106, can be moved continuously as plasticconcrete is continuously added to the insulated concrete slip forms orthe insulated concrete slip forms can be moved intermittently with eachnew lift of concrete.

The insulated concrete slip form 10 of the present invention isadvantageous over the prior art because it can be used in the samemanner as a prior art concrete slip form. Therefore, there is no newtraining required to install, move (i.e., raise) or remove these forms.However, the insulated concrete slip form 10 produces cured concretemore quickly and concrete having improved physical properties withoutusing increased amounts of portland cement, without adding expensivechemical additives and without adding energy to the curing concrete. Theinsulated concrete slip form 10 also provides the option of reducing theamount of portland cement in the concrete mix, and, therefore, reducingthe cost thereof while improving concrete properties and performance.

After the insulated concrete slip forms 100-106 have been movedupwardly, to set up for a new lift of concrete, a layer of insulatingmaterial 110, 112, 114, 116 is attached to the bottom of each of thefours insulated concrete slip forms, respectively. The layers ofinsulating material 110-116 surround the still curing concrete 118 fromthe previous concrete pour that is exposed by the uplifted insulatedconcrete slip forms 100-106. The layers of insulating material 110-116are of a length sufficient to cover, or substantially cover, the exposedprevious concrete 118 pour lift. As used herein, the term “substantiallycover” shall mean covering at least 80% of the surface area of anobject. Preferably, the layers of insulating material 110-116 are thesame length as the insulated concrete slip forms 110-106. However, undercertain conditions it may be desirable to have one or more additionallayers of insulating material (not shown) identical to the layers ofinsulating material 110-116 attached to the bottom of the layers ofinsulating material 110-116 so that they hang below the layers ofinsulating material 110-116 and surround the concrete 118 pour lift andpotentially other previous concrete pour lifts (not shown).Alternatively, the layers of insulating material 110-116 can have alength that is two or three times the length of the insulated concreteslip forms 100-106. The length is only dictated by the number ofconcrete pour lifts desired to be covered by the layers of insulatingmaterial 110-116 in order to retain the heat of hydration for a desiredtime.

The layers of insulating material 110-116 are made from any suitablematerial providing heat insulating properties, preferably a sheet ofclosed cell polymeric foam. The layers of insulating material 110-116are preferably made from closed cell foams including, but not limitedto, polyvinyl chloride, urethane, polyurethane, polyisocyanurate,phenol, polyethylene, polyimide or polystyrene. Such polymeric foampreferably has a density of 1 to 3 pounds per cubic foot, or more. Thelayers of insulating material 110-116 preferably have insulatingproperties equivalent to at least 0.25 inches of expanded polystyrenefoam, preferably equivalent to at least 0.5 inches of expandedpolystyrene foam, preferably equivalent to at least 1 inch of expandedpolystyrene foam, more preferably equivalent to at least 2 inches ofexpanded polystyrene foam, more preferably equivalent to at least 3inches of expanded polystyrene foam, most preferably equivalent to atleast 4 inches of expanded polystyrene foam, especially equivalent to atleast 8 inches of expanded polystyrene foam. There is no maximumthickness for the layers of insulating material 110-116 equivalent toexpanded polystyrene foam useful in the present invention. The maximumthickness is usually dictated by economics, weight, ease of handling andbuilding or structure design. However, for most applications a maximuminsulating equivalence of 8 inches of expanded polystyrene foam can beused. In another embodiment of the present invention, the layers ofinsulating material 110-116 have insulating properties equivalent toapproximately 0.25 to approximately 8 inches of expanded polystyrenefoam, preferably approximately 0.5 to approximately 8 inches of expandedpolystyrene foam, preferably approximately 1 to approximately 8 inchesof expanded polystyrene foam, preferably approximately 2 toapproximately 8 inches of expanded polystyrene foam, more preferablyapproximately 3 to approximately 8 inches of expanded polystyrene foam,most preferably approximately 4 to approximately 8 inches of expandedpolystyrene foam. These ranges for the equivalent insulating propertiesfor the layers of insulating material 110-116 include all of theintermediate values. Thus, the layers of insulating material 110-116used in another disclosed embodiment of the present invention haveinsulating properties equivalent to approximately 0.25 inches ofexpanded polystyrene foam, approximately 0.5 inches of expandedpolystyrene foam, approximately 1 inch of expanded polystyrene foam,approximately 2 inches of expanded polystyrene foam, approximately 3inches of expanded polystyrene foam, approximately 4 inches of expandedpolystyrene foam, approximately 5 inches of expanded polystyrene foam,approximately 6 inches of expanded polystyrene foam, approximately 7inches of expanded polystyrene foam, or approximately 8 inches ofexpanded polystyrene foam. Expanded polystyrene foam has an R-value ofapproximately 4 to 6 per inch thickness. Therefore, the layers ofinsulating material 110-116 should have an R-value of greater than 1.5,preferably greater than 4, more preferably greater than 8, mostpreferably greater than 12, especially greater than 20, more especiallygreater than 30, most especially greater than 40. The layers ofinsulating material 110-116 preferably have an R-value of approximately1.5 to approximately 40; more preferably between approximately 4 toapproximately 40; especially approximately 8 to approximately 40; moreespecially approximately 12 to approximately 40. The layers ofinsulating material 110-116 preferably have an R-value of approximately1.5, more preferably approximately 4, most preferably approximately 8,especially approximately 20, more especially approximately 30, mostespecially approximately 40.

The layers of insulating material 110-116 can also be made from arefractory insulating material, such as a refractory blanket, arefractory board or a refractory felt or paper. Refractory insulation istypically used to line high temperature furnaces or to insulate hightemperature pipes. Refractory insulating material is typically made fromceramic fibers made from materials including, but not limited to,silica, silicon carbide, alumina, aluminum silicate, aluminum oxide,zirconia, calcium silicate; glass fibers, mineral wool fibers,Wollastonite and fireclay. Refractory insulating material iscommercially available in various forms including, but not limited to,bulk fiber, foam, blanket, board, felt and paper form. Refractoryinsulation is commercially available in blanket form as FiberfraxDurablanket® insulation blanket from Unifrax I LLC, Niagara Falls, N.Y.,USA and RSI4-Blank and RSI8-Blank from Refractory SpecialtiesIncorporated, Sebring, Ohio, USA. Refractory insulation is commerciallyavailable in board form as Duraboard® from Unifrax I LLC, Niagara Falls,N.Y., USA and CS85, Marinite and Transite boards from BNZ MaterialsInc., Littleton, Colo., USA. Refractory insulation in felt form iscommercially available as Fibrax Felts and Fibrax Papers from Unifrax ILLC, Niagara Falls. The refractory insulating material can be anythickness that provides the desired insulating properties, as set forthabove. There is no upper limit on the thickness of the refractoryinsulating material; this is usually dictated by economics. However,refractory insulating material useful in the present invention can rangefrom 1/32 inch to approximately 2 inches. Similarly, ceramic fibermaterials including, but not limited to, silica, silicon carbide,alumina, aluminum silicate, aluminum oxide, zirconia, calcium silicate;glass fibers, mineral wool fibers, Wollastonite and fireclay, can besuspended in a polymer, such as polyurethane, latex, cement or epoxy,and used as a coating or a polymeric foam to create a refractoryinsulating material layer. Such a refractory insulating material layercan be used as the layers of insulating material 110-116 to blockexcessive ambient heat loads and retain the heat of hydration ofconcrete within the insulated concrete slip forms of the presentinvention. Ceramic fibers suspended in a polymer binder, such as latex,are commercially available as Super Therm®, Epoxotherm and HPC Coatingfrom Superior Products, II, Inc., Weston, Fla., USA.

The layers of insulating material 110-116 are preferably a multi-layermaterial with a first layer of refractory insulating material and asecond layer of polymeric foam insulating material. The layers ofinsulating material 110-116 more preferably each comprises a layer ofceramic fibers suspended in polymeric foam and a layer of expandedpolystyrene foam. The layers of insulating material 110-116 optionallycan each include a layer of radiant heat reflecting material. The layersof insulating material 110-116 are especially preferably each a concreteinsulating blanket having the insulating properties described above.Concrete insulating blankets can be made from one or more layers ofinsulating foam and optionally one or more layers of radiant heatreflective material, such as radiant heat reflective foils, such asaluminum foil. Concrete insulating blankets are commercially availableunder the designation Micro Foam from Pregis, Lake Forest, Ill.

The layers of insulating material 110-116 are left in place for a timesufficient for the curing concrete there within to further cure. Whilethe layers of insulating material 110-116 are in place, the layers ofinsulating material 110-116 retain at least a portion, preferably amajor portion, of the heat of hydration from the curing concrete 118surrounded by the layers of insulating material 110-116. By retaining atleast a portion of the heat of hydration, the concrete 118 surrounded bythe layers of insulating material 110-116 cures more quickly andachieves better physical properties than it would have had it been curedin a conventional concrete slip form; i.e., a non-insulated concreteslip form. This is true for conventional portland cement concrete, buteven more so for concrete including significant amounts of supplementarycementitious material, such as slag cement and/or fly ash, as describedbelow. Furthermore, it is desirable to leave the layers of insulatingmaterial 110-116 in place with the curing concrete 118 surroundedthereby for a period of approximately 3 hours to approximately 7 days,preferably approximately 3 hours to approximately 3 days, preferablyapproximately 6 hours to approximately 3 days, more preferablyapproximately 12 hours to approximately 3 days, especially approximately12 hours to approximately 2 days, more especially approximately 12 hoursto approximately 24 hours, most especially approximately 1 hour to 24hours. After the concrete 118 has cured to a desired amount or degree,the layers of insulating material 110-116 can be moved upwardly alongwith the insulated concrete slip forms 100-106, thereby exposing theconcrete 118 to the environment.

After the insulated concrete slip forms 100-106 have been movedupwardly, the layer of insulating material 108 is removed from the topof the insulated concrete slip forms and additional plastic concrete 120is added to the space defined between the insulated concrete slip forms.The layer of insulating material 108 is then placed back on top of theinsulated concrete slip forms 100-106 and the plastic concrete 120therein. The insulated concrete slip forms 100-106 and the layer ofinsulating material 108 are left in place until the concrete 120 hasachieve a desired amount or degree of cure. The insulated concrete slipforms 100-106 and the layer of insulating material 108 are left in placefor a period of time as disclosed above. After the concrete 120 withinthe insulated concrete slip forms 100-106 has achieved a desired amountor degree of cure, the insulated concrete slip forms 100-106 are thenmoved upwardly and the process repeated until the concrete structure hasachieve a desired height or size.

While the plastic concrete 120 of the top or most recent pour lift inthe insulated concrete slip forms 100-106 is poured fresh, it will reachits maximum temperature and maintain that temperature for a desiredamount of time; while the concrete 118 from the previous concrete pourlift bellow the insulated concrete slip forms 100-106 and surrounded bythe layers of insulating material 110-116, will either retain themaximum temperature for a desired amount of time or the temperature ofthe concrete will gradually be reduced. Therefore as the insulatedconcrete slip form 100-106 assembly elevates one lift at a time, thehottest concrete 120 is at the top of the slip form assembly where themost recent concrete lift is placed. Below, the concrete 118 ispreferably gradually cooled from its maximum temperature to ambienttemperature over several days. If the length of the layers of insulatedmaterial 110-116 is the same as the slip form 100-106, then the concrete118 bellow the most recent concrete 120 will also retain some of theheat of hydration. As the slip form advances upwardly, the concrete liftpour bellow the concrete 118 is exposed to the environment at the pointwhere it would have achieved the desired cure and strength properties.Once the concrete lift pour bellow the insulated layers 110-116 isexposed to the environment, it will loose the heat of hydration andmoisture at an accelerated rate, thereby slowing the curing and maturityprocess. If the concrete lift pours bellow the concrete 118 has notachieved the desired cure or properties and therefore cannot yet beexposed to the environment and allowed to lose heat and moisture, thenthe layers of insulated material 110-116 can be of greater length thanthe length of the insulated concrete slip forms 100-106. For example, ifthe layers of insulating material 110-116 are twice the length of theinsulated concrete slip forms 100-106, two previous concrete lift pourswould be covered by the layers of insulating material 110-116 therebypreventing heat and moisture loss for an additional period of time. Thepurpose of the insulated concrete slip forms 100-106, along with thelayers of insulating material 110-116, is to retain as much of the heatof hydration and moisture within the curing concrete structure for aslong as possible to accelerate concrete curing and reduce temperatureshrinkage cracking. Also, as the entire concrete slip form assemblymoves vertically upwardly, it will allow for a gradual exposure of thecuring concrete to the environment, so that the loss of heat andmoisture will not adversely impact the concrete curing and concreteproperties in the same manner as conventional non-insulating concreteslip forms do. By retaining the heat of hydration, the concrete maturesfaster thereby achieving its maximum properties much earlier than itwould in a conventional form. By gradually losing heat from the topconcrete 120 lift of the most recent concrete pour to the concrete 118lifts bellow, the concrete is cooled after it has achieved far greaterstrength than in a conventional form. Therefore, the gradual coolingachieved by the concrete slip forms 100-106 and layer of insulatingmaterial 110-116 of the present invention reduces, or completelyeliminates, temperature shrinkage cracking associated with conventionalconcrete curing while accelerating concrete curing and strength gain.

In some applications, it may be desirable to use an electrically heatedconcrete slip form. FIGS. 8-14 show a disclosed embodiment of anelectrically heated concrete slip form 200 in accordance with thepresent invention. The electrically heated concrete slip form 200comprises a rectangular concrete forming panel 202 supported by arectangular frame 208, which is made from a rigid material, such aswood, steel or aluminum. The frame 208 comprises two elongatelongitudinal members 210, 212 and two elongate transverse members 214,216. The longitudinal members 210, 212 and the transverse members 214,216 are attached to each other and to the panel 202 by any suitablemeans, such as by welding or bolting. The frame 208 also comprises atleast one, and preferably a plurality, of transverse bracing members218, 220, 222, 224, 226, 228, 230, 232, 234. The transverse bracingmembers 218-234 are attached to the longitudinal members 210, 212 and tothe panel 202 by any suitable means known in the art. The frame 208 alsoincludes bracing members 236, 238 and 240 (and a fourth bracing membernot shown). The bracing members 236, 238 extend between the transversemember 214 and the bracing member 218. The bracing members 236, 238 areattached to the transverse member 214 and the bracing member 218 and tothe panel 202 by any suitable means, such as by welding. The bracingmember 240 extends between the transverse member 216 and the bracingmember 234 (a second bracing member is used between the transversemember 216 and the bracing member 234 but is not shown). The bracingmember 240 is attached to the transverse member 216 and the bracingmember 234 and to the panel 202 by any suitable means, such as bywelding. The frame 208 helps prevent the panel 202 from flexing ordeforming under the hydrostatic pressure of plastic concrete placedbetween two identical forms 200. Aluminum frames of the foregoing designare available from Wall-Ties & Forms, Inc., Shawnee, Kans. and WallFormwork of Doka, Amstetten, Austria and Lawrenceville, Ga., USA.However, the particular design of the frame 208 is not critical to thepresent invention. There are many different designs of frames forconcrete slip forms and they are all applicable to the presentinvention.

The present invention departs from conventional prior art concrete slipforms, as explained below. The concrete forming panel 202 comprises aconcrete forming face or first panel 241 made from a heat conductingmaterial, such as aluminum or steel. Most prior art concrete forms usewood, plywood, wood composite materials, or wood or composite materialswith polymer coatings for the concrete forming panel of their concreteforms. Although wood, plywood, wood composite materials, plastic or woodor composite materials with polymer coatings are not very goodconductors of heat, they do conduct some heat. Therefore, wood, plywood,wood composite materials, and wood or composite materials with polymercoatings are considered useful materials from which to make the panel202, although they are not preferred. The first panel 241 has a firstprimary surface 242 for contacting plastic concrete and an oppositesecond primary surface 243. The first primary surface 242 is usuallysmooth and flat and is designed for contacting and forming plasticconcrete.

Disposed on the second primary surface 243 of the first panel 241 is anelectric resistance heating ribbon, tape or wire 244. The electricresistance heating wire 244 produces heat when an electric current ispassed through the wire. Electric resistance heating ribbons, tapes orwires are known and are the same type as used in electric blankets andother electric heating devices. The electric resistance heating wire 244is electrically insulated so that it will not make electrical contactwith the first panel 241. However, the electric resistance heating wire244 is in thermal contact with the first panel 241 so that when anelectric current is passed through the electric resistance heating wireit heats the first panel. The electric resistance heating wire 244 isplaced in a serpentine path on the second primary surface 243 of thefirst panel 241 so that the first panel is heated uniformly. Theelectric resistance heating wire 244 is of a type and the amount of wirein contact with the first panel 241 is selected so that the electricresistance heating wire will heat the panel to a temperature at least ashigh as the desired temperature of the concrete. The electrically heatedconcrete slip form 200 can also be used to accelerate the curing ofconventional concrete, as described below. Therefore, it is desirablethat the first panel 241 be able to be heated to temperatures sufficientto accelerate the curing of the concrete, such as at least as high as 50to 70° C.

Also disposed on the second primary surface 243 of the first panel 241is a layer of insulating material 246. The layer of insulating material246 is preferably a closed cell polymeric foam, such as expandedpolystyrene, polyisocyanurate, polyurethane, and the like. The layer ofinsulating material 246 has insulating properties equivalent to at least0.5 inches of expanded polystyrene foam; preferably equivalent to atleast 1 inch of expanded polystyrene foam, preferably equivalent to atleast 2 inches of expanded polystyrene foam, more preferably equivalentto at least 3 inches of expanded polystyrene foam, most preferablyequivalent to at least 4 inches of expanded polystyrene foam. The layerof insulating material 246 can have insulating properties equivalent toapproximately 0.5 inches to approximately 8 inches of expandedpolystyrene foam. The layer of insulating material 246 can haveinsulating properties equivalent to approximately 0.5 inches,approximately 1 inch, approximately 2 inches, approximately 3 inches orapproximately 4 inches of expanded polystyrene foam. The layer ofinsulating material 246 can have an R-value of greater than 2.5,preferably greater than 5, preferably greater than 10, more preferablygreater than 15, especially greater than 20. The layer of insulatingmaterial 246 preferably has an R-value of approximately 5 toapproximately 40; more preferably between approximately 10 toapproximately 40; especially approximately 15 to approximately 40; moreespecially approximately 20 to approximately 40. The layer of insulatingmaterial 246 preferably has an R-value of approximately 5, morepreferably approximately 10, especially approximately 15, mostpreferably approximately 20.

The electric resistance heating wire 244 is disposed between the layerof insulating material 246 and the second primary surface 243 of thefirst panel 241. Optionally, the surface of the layer of insulatingmaterial 246 opposite the second primary surface 243 of the first panel241 includes a layer of radiant heat reflective material (not shown),such as metal foil, especially aluminum foil. The layer of radiant heatreflective material helps direct the heat from the electric resistanceheating wire 244 toward the first panel 241. The layer of insulatingmaterial 246 can be preformed and affixed in place on the second primarysurface 243 of the first panel 241, or the layer of insulating materialcan be formed in situ, such as by spraying a foamed or self-foamingpolymeric material onto the second primary surface of the first panel.Another preferred material for the layer of insulating material 246 ismetalized plastic bubble pack type insulating material or metalizedclosed cell polymeric foam. Such material is commercially available asSpace Age® reflective insulation from Insulation Solutions, Inc., EastPeoria, Ill. 61611. The Space Age® product is available as two layers ofpolyethylene air bubble pack sandwiched between one layer of whitepolyethylene and one layer of reflective foil; two layers air bubblepack sandwiched between two layers of reflective foil; or a layer ofclosed cell polymeric foam (such as high density polyethylene foam)disposed between one layer of polyethylene film and one layer ofreflective foil. All three of these Space Age® product configurationsare useful in the present invention for the radiant heat reflectivematerial 246.

Disposed on the layer of insulating material 246 is a second panel 248of heat insulating material. The second panel 248 is disposed betweenthe layer of insulating material 246 and the frame 208. The second panel248 is made from heat insulating material or poor heat conductingmaterial including, but not limited to, wood, plywood, wood compositematerials and plastic. The second panel 248 is preferably made from asheet of high density overlay (HDO) plywood. The second panel 248 can beany useful thickness depending on the anticipated loads to which theform will be subjected. However, plywood thicknesses of ⅛ inch to ⅞inches can be used. The first panel 241, the layer of insulatingmaterial 246 and the second panel 248 are preferably laminated into asingle unit either adhesively or mechanically.

Use of the electrically heated concrete slip form 200 will now beconsidered in another disclosed embodiment. The electrically heatedconcrete slip form 200 can be used in the same manner as the insulatedconcrete slip forms 100-106 as described above. In another disclosedembodiment, as shown in FIG. 15, there is a first vertically orientedelectrically heated concrete slip form 200 and an identical secondvertically oriented electrically heated concrete slip form 250horizontally spaced from the first form to provide a concrete receivingspace there between. The electrically heated concrete slip forms 200,250 can be used to form conventional elevated structures or massconcrete structures, such as walls, piers, columns, etc. Theelectrically heated concrete slip forms 200, 250 sit on a concretefooting or concrete slab 252 (FIG. 15).

When greater control of the temperature of the electrically heatedconcrete slip forms 200, 250 is desired, a first temperature sensor 252in thermal contact with the second primary surface 243 of the firstpanel 241 of the electrically heated concrete slip form 200 ispreferably used (FIGS. 11, 12 and 15). The first temperature sensor 252is connected to a computing device 254 by an electric circuit, such asby the wires 256. The electrically heated concrete slip form 250 alsopreferably includes a temperature sensor 258 in thermal contact with thesecond primary surface 243 of the first panel 241 (FIG. 15). Thetemperature sensor 258 is connected to the computing device 254 by anelectric circuit, such as by the wires 260. The temperature sensors 252,258 allow the computing device 254 to continuously, or periodically,read and store the temperature of the panel 202 on each of theelectrically heated concrete slip forms 200, 250. The computing device254 is connected to a panel/blanket temperature controller 262 by anelectric circuit, such as by the wires 264. The temperature controller262 is connected to a source of electricity, such as 12, 24, 48, 120 or220 volts AC or 12 or 24 volts DC electric current, by wires (notshown). The lower voltages are desirable as they eliminate the chancesof electrocution by a worker touching the metal frame in a wetenvironment. The temperature controller 262 is also connected to theelectric resistance heating wire 244 of the electrically heated concreteslip form 200 by an electric circuit, such as by the wires 268. Thetemperature controller 262 is also connected to the electric resistanceheating wire 244 of the electrically heated concrete slip form 250 by anelectric circuit, such as by the wires 270. The computing device 254 andthe temperature controller 262 are configured and programmed such thatthe computing device controls the amount of heat produced by theelectrical resistance heating wire 244 in each of the electricallyheated concrete slip forms 200, 250. Thus, the computing device 254controls the amount of heat that is provided to plastic concretedisposed between the electrically heated concrete slip forms 200, 250. Athird temperature 272 sensor is optionally placed adjacent theelectrically heated concrete slip forms 200, 250. The third temperaturesensor 272 is connected to the computing device 256 by an electriccircuit, such as by the wires 274. The third temperature sensor 272measures the ambient temperature of the air surrounding the electricallyheated concrete slip forms 200, 250.

Operation of the electrically heated concrete slip forms 200, 250 invarious modes will now be considered. In its simplest mode, theelectrically heated concrete slip forms 200, 250 (FIGS. 8-12) areoperated in an on/off mode. In this mode, a constant amount ofelectricity is provided to the electric resistance heating wire 244 ofeach of the electrically heated concrete slip forms 200, 250 (FIGS.8-14) so that a constant amount of heat is provided to the panel 202 ofeach of the electrically heated concrete slip forms 200, 250. Thus, anoperator can turn the heat on and turn the heat off. For this mode ofoperation, no computing device and no temperature sensors are required;a simple controller 262 with an on/off switch (not shown) will suffice.

In the next mode of operation, various fixed amounts of electricity areprovided to the electric resistance heating wire 244 of each of theelectrically heated concrete slip forms 200, 250, such as a low amount,a medium amount and a high amount or the electric resistance heatingwire is energized for different periods of time, such as a short, mediumand long time. This can be done by providing a different voltage to theelectric resistance heating wire 244 or by changing the amount of timethat the electric resistance heating wire is energized in each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-12). Thus, anoperator can select one of several predetermined amounts of heatprovided to the panel 902 of each of the electrically heated concreteslip forms 200, 250. For this mode of operation, no computing device andno temperature sensors are required; a simple controller 262 with aselector switch (not shown) will suffice.

The next mode of operation is for the panel 202 of each of theelectrically heated concrete slip forms 200, 250 to be held at aconstant desired temperature. For this more of operation, the computingdevice 254 is programmed to perform the process shown in FIG. 16.

As shown in FIG. 16, the process starts at the block 300 and proceeds tothe block 302 where a desired end time and a desired temperature areentered. These values are stored in memory locations, such as in the RAMmemory of the computing device 254. The end time is the desired amountof temperature controlled curing time for the concrete between theelectrically heated concrete slip forms 200, 250. The desiredtemperature is the temperature at which the panel 202 of each of theelectrically heated concrete slip forms 200, 250 will be maintained eventhough the ambient temperature may change. Any desired temperature canbe selected. However, it is preferred that the desired temperature ispreferably about 50° C.; more preferably about 55° C.; most preferablyabout 60° C.; especially about 65° C.; more especially about 70° C.;most especially about 63° C. The process proceeds from the block 302 tothe block 304 where the clock is initialized to time equal to zero andthe clock is started. The clock measures the elapsed time from when theplastic concrete between the electrically heated concrete slip forms200, 250 is subjected to the controlled temperature curing process.

The process proceeds from the block 304 to the block 306 where the clockis read. The time that is read from the clock is then stored in a memorylocation, such as in the RAM memory of the computing device 254. Theprocess proceeds from the block 306 to the decision block 308. A desiredend time for terminating the process, such as 1 hour to 7 days, isentered into a memory location in the computing device 254 at the block302. At the block 308, the clock time stored in the memory location iscompared to the end time stored in the memory location of the computingdevice 254. If the clock time is less than the end time, the processproceeds to the block 312. If the clock time is greater than or equal tothe end time, the process proceeds to the block 310 where the process isterminated.

At the block 312, the temperature from the panel temperature sensors252, 258 is read and stored in memory locations, such as in the RAMmemory of the computing device 254. The process then proceeds from theblock 312 to the decision block 314. At the decision block 314, thetemperature from the panel temperature sensors 252, 258 is compared tothe stored desired temperature. If the measured panel temperature isless than the stored desired temperature, the process proceeds to theblock 316. When this condition is encountered, the panel temperature isless than the desired temperature, so it is necessary to provideadditional heat to the panel 202 of each of the electrically heatedconcrete slip forms 200, 250 (FIGS. 8-12). At the block 316 thetemperature of the panel 202 of each of the electrically heated concreteslip forms 200, 250 is increased. This can be done by the computingdevice 254 sending a signal to the panel/blanket temperature controller262 providing an increased electrical voltage to the electricalresistance heating wire 244 or by increasing the time that theelectrical resistance heating wire is energized of each of theelectrically heated concrete slip forms 200, 250. The process thenproceeds from the block 316 to the block 318. At the block 318, apredetermined wait time is executed before the process proceeds from theblock 318 to the block 306. The wait time can be any desired time thatis suitable for the panel temperature being measured, such as one secondor ten seconds or 30 seconds or one minute or one hour. If the actualmeasured panel temperature is greater than or equal to the desiredtemperature, the process proceeds from the decision block 314 to thedecision block 320.

At the decision block 320, if the actual measured panel temperature isgreater than the stored desired temperature, the process proceeds to theblock 322. At the block 322, the temperature of the panel 202 of each ofthe electrically heated concrete slip forms 200, 250 is decreased. Thiscan be done by the computing device 254, sending a signal to thepanel/blanket temperature controller 256, to decrease the temperature ofthe electrical resistance heating wire 244 in each of the electricallyheated concrete slip forms 200, 250 (FIG. 8-12). This can be done by thetemperature controller 262 providing a reduced electrical voltage to theelectrical resistance heating wire 244 or by reducing the time that theelectrical resistance heating wire is energized for of each of theelectrically heated concrete slip forms 200, 250. The process thenproceeds from the block 322 to the block 324. At the block 324, apredetermined wait time is executed before the process proceeds from theblock 324 to the block 306. The wait time can be any desired time thatis suitable for the temperature of the panel 202 being measured, such asone second or ten seconds or 30 seconds or one minute or one hour. Ifthe actual measured panel temperature is not greater than the storeddesired temperature, the process proceeds to the block 324. At thedecision block 320, if the actual measured panel temperature is lessthan or equal to the stored desired temperature, the process proceeds tothe block 322. At the block 322, the temperature of the panel 202 ofeach of the electrically heated concrete slip forms 200, 250 isdecreased. This can be done by the computing device 254 sending a signalto the panel/blanket temperature controller 262 providing a reducedelectrical voltage to the electrical resistance heating wire 244 or byreducing the time that the electrical resistance heating wire isenergized of each of the electrically heated concrete slip forms 200,250. The process then proceeds from the block 322 to the block 324.

FIG. 14 shows a graph of a disclosed embodiment of a desired curingtemperature profile for concrete as a function of time. In this graph,the temperature of the concrete is shown on the vertical axis andelapsed concrete curing time is shown on the horizontal axis. Theintersection of the vertical and horizontal axes represents 0° C.concrete temperature and zero elapsed concrete curing time. Ambienttemperature is also shown on this graph. The peaks and troughs of theambient temperature represent the daily (i.e., day to night) fluctuationof ambient temperature. As can be seen in this graph, the temperature ofthe concrete initially increases quite rapidly over a relatively shorttime, such as 1 to 3 days. After a period of time, the concretetemperature reaches a maximum and then slowly drops to ambienttemperature over an extended period, such as 1 to 7 days, preferably 1to 14 days, more preferably 1 to 28 days, especially 3 to 5 days or moreespecially 5 to 7 days. The maximum temperature will vary depending onthe composition of the concrete mix. However, it is desirable that themaximum temperature is at least 35° C., preferably, at least 40° C., atleast 45° C., at least 50° C., at least 55° C., at least 60° C. or atleast 65° C. The maximum concrete temperature should not exceed about70° C. The maximum concrete temperature is preferably about 70° C.,about 69° C., about 68° C., about 67° C., about 66° C., about 65° C.,about 64° C., about 63° C., about 62° C., about 61° C., about 60° C. orabout 60 to about 70° C. Furthermore, it is desirable that thetemperature of the concrete is maintained above approximately 30° C.,approximately 35° C., approximately 40° C., approximately 45° C.,approximately 50° C., approximately 55° C. or approximately 60° C. for 1to approximately 4 days from the time of concrete placement, preferably1 to approximately 3 days from the time of concrete placement, morepreferably about 1 hour to about 3 days from the time of concreteplacement, most preferably about 1 hour to about 2 days from the time ofconcrete placement, especially about 1 hour to about 24 hours. It isalso desirable that the temperature of the concrete is maintained aboveapproximately 30° C. for 1 to approximately 7 days from the time ofconcrete placement, preferably above approximately 35° C. for 1 toapproximately 7 days from the time of concrete placement, morepreferably above approximately 40° C. for 1 to approximately 7 days fromthe time of concrete placement, most preferably above approximately 45°C. for 1 to approximately 7 days from the time of concrete placement. Itis also desirable that the temperature of the concrete be maintainedabove ambient temperature for 1 to approximately 3 days from the time ofconcrete placement; 1 to approximately 5 days from the time of concreteplacement, for 1 to approximately 7 days from the time of concreteplacement, for 1 to approximately 14 days from the time of concreteplacement, preferably approximately 3 to approximately 14 days from thetime of concrete placement, especially approximately 7 to approximately14 days from the time of concrete placement. It is also desirable thatthe temperature of the concrete be maintained above ambient temperaturefor approximately 3 days, approximately 5 days, approximately 7 days orapproximately 14 days from the time of concrete placement. It is furtherdesirable that the temperature of the concrete be reduced from themaximum temperature to ambient temperature gradually, such as inincrements of approximately 0.5 to approximately 5° C. per day,preferably approximately 1 to approximately 2° C. per day, especiallyapproximately 1° C. per day. The electrically heated concrete slip formis preferably kept on the curing concrete until the concrete is strongenough such that cracking due to temperature shrinkage will not occurfrom further cooling. Different curing temperature profiles may apply todifferent concrete mix designs and/or different materials used for thecementitious portion of the concrete mix in order to achieve a desiredconcrete strength or a desired concrete strength within a desired periodof time in different weather conditions. However, all curing temperatureprofiles in accordance with the present invention will have the samegeneral shape as shown in FIG. 14 relative to ambient temperature. Thus,as used herein the term “temperature profile” includes increasing theconcrete temperature above ambient temperature over a period of timefollowed by decreasing the concrete temperature over a period of time,preferably to ambient temperature, wherein the slope of a line plottingtemperature versus time during the temperature increase phase is greaterthan the absolute value of the slope of a line plotting temperatureversus time during the temperature decrease phase. Furthermore, theabsolute value of the slope of a line plotting temperature versus timeduring the temperature decrease phase of the temperature profile in aconcrete form in accordance with the present invention is less than theabsolute value of the slope of a line plotting temperature versus timeif all added heat were stopped and the concrete were simply allowed tocool in a conventional concrete form; i.e., an uninsulated concreteform, under the same conditions. The term “temperature profile” includesthe specific ranges of temperature increase and ranges of temperaturedecrease over ranges of time as set forth above with respect to FIG. 17.The term “temperature profile” includes increasing the temperature ofcuring concrete in a concrete form or mold to a maximum temperature atleast 10% greater than the maximum temperature the same concrete mixwould have reached in a conventional (i.e., non-insulated) concrete formor mold of the same configuration. The term “temperature profile” alsoincludes reducing the temperature of curing concrete in a concrete formor mold from its maximum temperature at a rate slower than the rate thesame concrete mix would reduce from its maximum temperature in aconventional (i.e., non-insulated) concrete form or mold of the sameconfiguration. The principle behind concrete maturity is therelationship between strength, time, and temperature in young concrete.Maturity is a powerful and accurate means to predict early strengthgain. Concrete maturity is measured as “equivalent age” and is given intemperature degrees×hours (either ° C.-Hrs or ° F.-Hrs). The term“temperature profile” includes controlling the temperature of curingconcrete so that at 3 days it has a concrete maturity or equivalent ageat least 25% greater than the same concrete mix would have in aconventional (i.e., non-insulated) concrete form or mold of the sameconfiguration under the same conditions; preferably at least 30%greater, more preferably at least 35% greater, most preferably at least40% greater, especially at least 45% greater, more especially at least50% greater. The term “temperature profile” includes controlling thetemperature of curing concrete so that at 3 days it has a concretematurity or equivalent age about 70% greater than the same concrete mixwould have when cured in accordance with ASTM C-39; preferably at least75% greater, more preferably at least 80% greater, most preferably atleast 85% greater, especially at least 90% greater, more especially atleast 95% greater, most especially at least 100% greater. The term“temperature profile” includes controlling the temperature of curingconcrete so that at 7 days it has a concrete maturity or equivalent ageabout 70% greater than the same concrete mix would have when cured inaccordance with ASTM C-39; preferably at least 75% greater, morepreferably at least 80% greater, most preferably at least 85% greater,especially at least 90% greater, more especially at least 95% greater,most especially at least 100% greater. The term “temperature profile”specifically does not include adding a constant amount of heat to theconcrete followed by stopping adding heat to the concrete, such as wouldbe involved when turning an electrically heated blanket or heatedconcrete form on and then turning the heated blanket or heated concreteform off. The term “temperature profile” specifically does not includemaintaining the concrete at a constant temperature followed by stoppingadding heat to the concrete, such as would be involved when turning anelectrically heated blanket or heated concrete form on and then turningthe heated blanket or heated concrete form off. The term “temperatureprofile” also specifically does not include heating the concrete to adesired temperature and then stopping adding heat to the concrete.

FIG. 18 shows an alternate disclosed embodiment of a flow diagram for aprocess for controlling the heat provided to concrete so that thetemperature of the concrete can be controlled to follow a desiredpredetermined temperature profile, such as that shown in FIG. 17, usingthe electrically heated concrete slip forms 200, 250 (FIGS. 8-15). Thecomputing device 254 is programmed so that it will perform the processshown by this flow diagram.

The process starts at the block 400 and proceeds to the block 402 wherea clock is initialized to time equal to zero and the clock is started.The clock measures the elapsed time from when the concrete is placedinto the insulated concrete form or mold. This elapsed time therefore isa measure of the elapsed time for the curing of the concrete.

The process proceeds from the block 402 to the block 404 where the clockis read. The time that is read from the clock is then stored in a memorylocation, such as in the RAM memory of the computing device 254. Theprocess proceeds from the block 404 to the decision block 406. A desiredend time for terminating the process, such as 1 hour to 7 days, ispreprogrammed into a memory location in the computing device 254. At theblock 406, the clock time stored in the memory location is compared tothe end time stored in the memory location of the computing device 254.If the clock time is less than the end time, the process proceeds to theblock 408. If the clock time is greater than or equal to the end time,the process proceeds to the block 410 where the process is terminated.

At the block 408, the temperature from the temperature sensor 252, 258on second primary surface 206 of the plate 202 of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15) is readand stored in a memory location, such as in the RAM memory of thecomputing device 254. The process then proceeds from the block 408 tothe block 412.

At the block 412 the temperature from the predetermined temperatureprofile is determined for the clock time stored in the memory location.This can be done from the temperature profile curve, such as the curveshown in FIG. 17. The clock time is found on the horizontal axis and thetemperature is determined by finding the vertical axis component of thecurve for the time corresponding to the clock time. When thistemperature is determined, it is stored in a memory location, such as inthe RAM memory of the computing device 254. In an alternate disclosedembodiment, instead of using a graph, such as shown in FIG. 17, thetemperature profile can be in the form of a lookup table. The lookuptable lists a range of times and a profile temperature corresponding toeach range of time. The process then proceeds from the block 412 to thedecision block 414.

At the decision block 414 the temperature of the concrete, which in thiscase is assumed to be the temperature of the plate 202 of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15) asmeasured by the sensors 252, 258, is compared to the profile temperaturecorresponding to the stored clock time. If the plate 202 temperature isgreater than the profile temperature, the process proceeds to the block418. When this condition is encountered, the temperature of the concreteis greater than the profile temperature, so it is not necessary toprovide additional heat to the concrete so that the temperature of theconcrete will equal the profile temperature. Therefore, at the block 418the temperature of the plate 202 on each of the electrically heatedconcrete slip forms 200, 250 (FIGS. 8-15) is decreased. This can be doneby the computing device 254 sending a signal to the temperaturecontroller 262 to reduce the temperature of the plate 202 of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15). This isdone by the temperature controller 262 providing a reduced electricalvoltage to the electrical resistance heating wire 244 of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15) orreducing the time that the electrical resistance heating wire isenergized. The process then proceeds from the block 418 to the block420. At the block 420, a predetermined wait time is executed before theprocess proceeds from the block 420 to the block 404. The wait time canbe any desired time that is suitable for the concrete temperature beingmeasured, such as one second or ten seconds or 30 seconds or one minuteor one hour. If the plate 202 temperature of each of the electricallyheated concrete slip forms 200, 250 (FIGS. 8-15) is less than or equalto the profile temperature, the process proceeds to the decision block416.

At the decision block 416, the plate 202 temperature of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15) iscompared to the profile temperature corresponding to the stored clocktime. If the plate 202 temperature is equal to the profile temperature,the process proceeds from the block 416 to the block 420. If the plate202 temperature is not equal to the profile temperature, the processproceeds to the decision block 422.

At the decision block 422, the plate 202 temperature is compared to theprofile temperature. If the plate 202 temperature is greater than orequal to the profile temperature, the process proceeds to the block 420.If the plate 202 temperature is less than the profile temperature, theprocess proceeds to the block 424.

At the block 424 the temperature of the plate 202 of each of theelectrically heated concrete slip forms 200, 250 (FIGS. 8-15) isincreased. This can be done by the computing device 254 sending a signalto the temperature controller 262 to increase the temperature of theplate 202 of each of the electrically heated concrete slip forms 200,250 (FIGS. 8-15). This can be done by the temperature controller 262providing a greater electrical voltage to the electrical resistanceheating wire 244 of each of the electrically heated concrete slip forms200, 250 (FIGS. 8-15) or increasing the time that the electricalresistance heating wire is energized. The process then proceeds from theblock 424 to the block 426.

At the decision block 426, a predetermined wait time is executed beforethe process proceeds from the block 426 to the block 404. The wait timecan be any desired time that is suitable for the concrete temperaturebeing measured, such as one second or ten seconds or 30 seconds or oneminute or one hour. The process then proceeds from the block 426 to theblock 404 where a new clock time is read.

The foregoing process regulates the heat provided by the electricallyheated concrete slip forms 200, 250 (FIGS. 8-15) so that the temperatureof the concrete is equal to the profile temperature at any given time.When the temperature of the concrete is less than the profiletemperature at a given time, the electrically heated concrete slip forms200, 250 (FIGS. 8-15) provide heat to the concrete until the temperatureof the concrete is equal to the profile temperature. When thetemperature of the concrete is greater than the profile temperature at agiven time, no additional heat, or a reduced amount of heat, is providedto the concrete. Thus, the concrete temperature is continuouslymonitored and adjusted so that over time the concrete temperature willfollow the predetermined temperature profile. Thus, over a predeterminedtime period the concrete temperature will be maintained at predeterminedlevels and then gradually reduce to ambient temperature at apredetermined rate.

After the concrete has achieved a desired amount or degree of cure, theelectrically heated concrete slip forms, 200, 250 are moved; i.e.,raised, to a desired height and additional plastic concrete 274 isplaced in the next concrete lift between the electrically heatedconcrete slip forms. As with the insulated concrete slip forms 100-106,a layer of insulating material 500, 502, identical to the layers ofinsulating material 110-116, is attached to the bottom of each of theelectrically heated concrete slip forms, 200, 250 so that the layers ofinsulating material cover and/or surround the concrete 276 exposed whenthe electrically heated concrete slip forms are raised. As with theembodiment disclosed above, the layer of insulating material 500, 502attached to the bottom of the electrically heated concrete slip forms,200, 250 is preferably a concrete insulating blanket. In anotherembodiment, the layer of insulating material 500, 502 attached to thebottom of either each of the insulated concrete slip forms 100-106 oreach of the electrically heated concrete slip forms, 200, 250 arepreferably electrically heated blankets. An electrically heated blanketsuitable for use in the present invention is disclosed in U.S. Pat. Nos.7,183,524 and 7,230,213 (the disclosures of which are both incorporatedherein by reference in their entirety). Infrared or far infrared heatingblankets also can be used due to their relatively low voltage andrelatively low power consumption characteristics. The lower voltages arepreferred as they reduce or eliminate the chances of electrocution by aworker.

While the plastic concrete 274 of the top or most recent pour lift inthe electrically heated concrete slip forms 200, 250 is poured fresh, itwill reach its maximum temperature and maintain that temperature for adesired amount of time; while the concrete 276 from the previousconcrete pour lift bellow the electrically heated concrete slip formsand surrounded by the layers of insulating material 500, 502 will eithermaintain the maximum temperature and/or gradually reduce the temperatureof the concrete. Therefore, as the electrically heated concrete slipform 200, 250 assembly elevates one lift at a time, the hottest concrete274 is at the top of the electrically heated concrete slip forms wherethe most recent concrete lift is placed. Below, the concrete 276 isgradually cooled from its maximum temperature to ambient temperatureover a period of time, such as several hours to several days. If thelength of the layers of insulated material 500, 502 is the same as thelength of the electrically heated concrete slip forms, 200, 250, theconcrete 276 bellow the most recently poured concrete 274 will alsoretain some of the concrete's heat of hydration. As the electricallyheated concrete slip forms 200, 250 advance upwardly, the concrete 276lift pour bellow the concrete 274 is exposed to the environment at thepoint where it would have achieved the desired cure and strengthproperties. Once the concrete 276 lift pour bellow the layers ofinsulating material 500, 502 is exposed to the environment, it willloose the heat of hydration and moisture at an accelerated rate, therebyslowing the curing and maturity process. If the concrete 276 lift pourbellow the concrete 274 has not achieved the desired amount or degree ofcure or the desired properties and therefore cannot yet be exposed tothe environment and allowed to lose its heat and moisture, the layers ofinsulated material 500, 502 can be made of a greater length than thelength of the electrically heated concrete slip forms 200, 250. Forexample, if the layers of insulating material 500, 502 are twice thelength of the electrically heated concrete slip forms 200, 250, twoprevious concrete pour lifts would be covered by the layers ofinsulating material thereby preventing heat and moisture loss for alonger period of time. The purpose of the electrically heated concreteslip forms 200, 250 in combination with the layers of insulatingmaterial 500, 502 is to retain as much of the heat of hydration andmoisture within the curing concrete 274, 276 structure for as long aspossible, to accelerate concrete curing and reduce temperature shrinkagecracking. Also, as the entire concrete form assembly moves verticallyupwardly, it will allow for a gradual exposure of the curing concrete tothe environment, so that the loss of heat and moisture will notadversely impact the concrete curing and concrete properties in the samemanner as conventional concrete slip forms. By causing the concrete tofollow a predetermined temperature profile and by retaining the heat ofhydration, the concrete matures faster thereby achieving its maximumproperties much earlier than it would in a conventional (non-insulated)slip form. By gradually reducing the temperature of the top concrete 274lift of most recent concrete pour to the concrete 276 lift bellow, theconcrete is cooled after it has achieved far greater strength than in aconventional slip form. Therefore, the gradual cooling achieved by theelectrically heated concrete slip forms 200, 250 and the layers ofinsulating material 500, 502 of the present invention reduces, orcompletely eliminates, temperature shrinkage cracking associated withconventional concrete curing while accelerating concrete curing andstrength gain.

When electrically heated blankets are used as the layers of insulatingmaterial 500, 502 with either the insulated concrete slip forms 100-106or the electrically heated concrete slip forms, 200, 250, theelectrically heated blankets can be operated in several different modes.In its simplest mode, the electrically heated blankets 500, 502 (FIG.15) are operated in an on/off mode. In this mode, a constant amount ofelectricity is provided to the electrical resistance heating wire ofeach of the electrically heated blankets so that a constant amount ofheat is provided to the concrete 276. Thus, an operator can turn theheat on and turn the heat off. For this mode of operation, no computingdevice and no temperature sensors are required; a simple controller withan on/off switch will suffice.

In the next mode of operation, various fixed amounts of electricity areprovided to the electrical resistance heating wire of each of theelectrically heated blankets 500, 502, such as a low amount, a mediumamount and a high amount. This can be done by providing a differentvoltage to the resistance heating wire or by changing the amount of timethat the resistance heating wire is energized in each of theelectrically heated blankets 500, 502. Thus, an operator can select oneof several predetermined amounts of heat provided to the electricallyheated blankets 500, 502. For this mode of operation, no computingdevice and no temperature sensors are required; a simple controller witha selector switch will suffice.

The next mode of operation is for the electrically heated blankets 500,502 to be held at a constant desired temperature. For this mode ofoperation, the computing device 254 is programmed to perform the processshown in FIG. 16, as described above, except the computing device andthe temperature controller 262 control the electrically heated blankets500, 502 in addition to controlling the electrically heated concreteslip forms 200, 250. The electrically heated blanket 500 includes afourth temperature sensor 504 connected to the computing device 254 byan electric circuit, such as by the wires 506. The electrically heatedblanket 502 includes a fifth temperature sensor 508 connected to thecomputing device 254 by an electric circuit, such as by the wires 510.The panel/blanket temperature controller 262 is connected to theelectrical resistance heating wire of the electrically heated blanket500 by an electric circuit, such as by the wires 512. The panel/blankettemperature controller 262 is connected to the electrical resistanceheating wire of the electrically heated blanket 502 by an electriccircuit, such as by the wires 514. Thus, when the computing device 254is programmed to perform the process of FIG. 16, the process regulatesthe heat provided by the electrically heated blankets 500, 502 so thatthe temperature of the concrete is maintained at a constant temperature.In this case the temperature of the electrically heated blankets 500,502 will preferably be lower than the temperature of the electricallyheated concrete slip forms 200, 250.

The next mode of operation is for the temperature of the electricallyheated blankets 500, 502 to follow a predetermined temperature profile.FIG. 18 shows a flow diagram for a process for controlling the heatprovided to concrete so that the temperature of the concrete can becontrolled to match a desired predetermined temperature profile, such asthat shown in FIG. 17, using the electrically heated blankets 500, 502.The computing device 254 is programmed so that it will perform theprocess shown by this flow diagram.

Thus, when the computing device is programmed to perform the process ofFIG. 18, the process regulates the heat provided by the electricallyheated concrete slip forms 200, 250 and the electrically heated blankets500, 502 so that the temperature of the concrete 274, 276 is equal tothe profile temperature at any given time. When the temperature of theconcrete 274 is less than the profile temperature at a given time, theelectrically heated concrete slip forms 200, 250 provide heat to theconcrete until the temperature of the concrete is equal to the profiletemperature. Similarly, when the temperature of the concrete 276 is lessthan the profile temperature at a given time, the electrically heatedblankets 500, 502 provide heat to the concrete until the temperature ofthe concrete is equal to the profile temperature. When the temperatureof the concrete 274, 276 is greater than the profile temperature at agiven time, no additional heat, or a reduced amount of heat, is providedto the concrete. Thus, the temperature of the two portions of concrete274, 276 is separately and continuously monitored and separatelyadjusted so that over time the temperature of the two portions ofconcrete will follow the predetermined temperature profile for each oftheir respective time periods. Thus, over a predetermined time periodthe temperature of each portions of the concrete 274, 276 will beseparately maintained at predetermined levels and then the temperatureof the concrete will gradually be reduced to ambient temperature at apredetermined rate.

When both the electrically heated concrete slip forms 200, 250 and theelectrically heated blankets 500, 502 are used together, the computingdevice 254 is programmed so that it can control the temperature of theelectrically heated concrete slip forms and the electrically heatedblankets separately and independently. Also, the concrete curing timefor the concrete 274 disposed between the electrically heated concreteslip forms 200, 250 is kept separate from the concrete curing time forthe concrete 276 disposed between the electrically heated blankets 500,502. Thus, the concrete 274 disposed between the electrically heatedconcrete slip forms 200, 250 will be on a different portion of thepredetermined temperature profile (preferably at a higher temperature)than the concrete 276 disposed between the electrically heated blankets500, 502 (preferably at a lower temperature). Thus, the temperature ofthe electrically heated concrete slip forms 200, 250 can be differentthan the temperature of the electrically heated blankets 500, 502,depending on where each portion of the curing concrete fits on thepredetermined concrete temperature profile.

The predetermined time associated with the predetermined concretetemperature profile is equal to the length of time that the electricallyheated concrete slip forms 200, 250 stay in place before they are moved(i.e., raised) for the next concrete lift pour above. If a constructionschedule requires a shorter time for each lift pour then the layers ofinsulating material 500, 502 bellow the electrically heated concreteslip forms 200, 250 can be electrically heated blankets. Theelectrically heated blankets can be independently controlled by anothercontroller, or by the same controller 262 as the electrically heatedconcrete slip forms 200, 250. In this configuration the electricallyheated concrete slip forms 200, 250 will be controlled so that the topmost recent concrete 274 lift follows the predetermined temperatureprofile of the initial period up to the time that the electricallyheated concrete slip forms are moved upwardly, while the concrete 276covered by the electrically heated blankets 500, 502 covering theconcrete 276 lift bellow the electrically heated concrete slip forms200, 250 follows the predetermined temperature profile for the timeperiod corresponding to the time after which the electrically heatedconcrete slip forms are moved upwardly until the next time theelectrically heated concrete slip forms are moved upwardly. This can beachieved using the same temperature profile with a dual controller forboth the electrically heated concrete slip forms 200, 250 and theelectrically heated blankets 500, 502, or separate temperature profilesassociated with the concrete 274 and the concrete 276 and separatecontrollers (not shown).

As described above, the electrically heated concrete slip forms 200, 250and the electrically heated blankets 500, 502 are moved intermittentlywith each new lift of concrete. However, it is specifically contemplatedthat the electrically heated concrete slip forms 200, 250 and theelectrically heated blankets 500, 502 can be moved continuously asplastic concrete is continuously added to the heated concrete slipforms. In this mode of operation, the electrically heated concrete slipforms 200, 250 and the electrically heated blankets 500, 502 are held ata constant temperature, with the electrically heated blankets being at alower temperature than the electrically heated concrete slip forms. Inthis mode of operation, it is desired that the electrically heatedelectrically heated blankets 500, 502 be approximately 5° C. lower thanthe temperature of the electrically heated concrete slip forms 200, 250,preferably approximately 10° C. lower, more preferably approximately 15°C. lower, most preferably approximately 20° C. lower. Of course, thesize of the electrically heated concrete slip forms 200, 250, the lengthof the electrically heated blankets 500, 502 and the speed that theelectrically heated concrete slip forms and the electrically heatedblankets move will determine the amount of time that the concrete isexposed to these two different heating zones.

In the electrically heated blankets 500, 502 and the electrically heatedconcrete slip forms 200, 250 the electrical resistance heating element,such as the electric resistance heating wire 244, can be substitutedwith an infrared producing device, such as disclosed in U.S. Pat. No.4,602,238 and U.S. Patent Application Publication No. 2009/0324811 (thedisclosures of which are both incorporated herein by reference) or a farinfrared producing device, such as disclosed in U.S. Pat. Nos. 7,009,155and 7,827,675 and U.S. Patent Application Publication Nos. 2003/0049473;2003/0155347; 2009/0312822 and 2010/0062667 (the disclosures of whichare all incorporated herein by reference in their entirety).

While the present invention can be used with conventional concretemixes; i.e., concrete in which portland cement is the only cementitiousmaterial used in the concrete, it is preferred as a part of the presentinvention to use the concrete or mortar mixes disclosed below ordisclosed in applicant's co-pending patent application Pub. No. US2013/0119576 (the disclosure of which is incorporated herein byreference in its entirety). Specifically, the concrete mix in accordancewith the present invention comprises cementitious material, aggregateand water sufficient to hydrate the cementitious material. The amount ofcementitious material used relative to the total weight of the concretevaries depending on the application and/or the strength of the concretedesired. Generally speaking, however, the cementitious materialcomprises approximately 25% to approximately 40% by weight of the totalweight of the concrete, exclusive of the water, or 300 lbs/yd³ (177kg/m³) of cement to 1,200 lbs/yd³ (710 kg/m³) of cement. In Ultra HighPerformance Concrete, the cementitious material exceeds the 40% byweight of the total weight of the concrete. The water-to-cement ratio byweight is usually approximately 0.25 to approximately 0.7. Relativelylow water-to-cement materials ratios by weight lead to higher strengthbut lower workability, while relatively high water-to-cement materialsratios by weight lead to lower strength, but better workability. Forhigh performance concrete and ultra high performance concrete, lowerwater-to-cement ratios are used, such as approximately 0.15 toapproximately 0.25. Aggregate usually comprises 70% to 80% by volume ofthe concrete. In Ultra High Performance concrete the aggregate is lessthan 70% of the concrete by volume. However, the relative amounts ofcementitious material to aggregate to water are not a critical featureof the present invention; conventional amounts can be used.Nevertheless, sufficient cementitious material should be used to produceconcrete with an ultimate compressive strength of at least 1,000 psi,preferably at least 2,000 psi, more preferably at least 3,000 psi, mostpreferably at least 4,000 psi, especially up to about 10,000 psi ormore. In particular, Ultra High Performance concrete, concrete panels orconcrete elements with compressive strengths of over 20,000 psi can becast and cured using the method of the present invention.

The aggregate used in the concrete used with the present invention isnot critical and can be any aggregate typically used in concrete. Theaggregate that is used in the concrete depends on the application and/orthe strength of the concrete desired. Such aggregate includes, but isnot limited to, fine aggregate, medium aggregate, coarse aggregate,sand, gravel, crushed stone, lightweight aggregate, recycled aggregate,such as from construction, demolition and excavation waste, and mixturesand combinations thereof.

The reinforcement of the concrete used with the present invention is nota critical aspect of the present invention and thus any type ofreinforcement required by design requirements can be used. Such types ofconcrete reinforcement include, but are not limited to, deformed steelbars, cables, post tensioned cables, pre-stressed cables, fibers, steelfibers, mineral fibers, synthetic fibers, carbon fibers, steel wirefibers, mesh, lath, and the like.

The preferred cementitious material for use with the present inventioncomprises portland cement; preferably portland cement and one or morepozzolans; and more preferably portland cement, slag cement and one ormore pozzolans. The cementitious material preferably comprises a reducedamount of portland cement and increased amounts of recycledsupplementary cementitious materials; i.e., slag cement and/or fly ash.This results in cementitious material and concrete that is moreenvironmentally friendly. The portland cement can also be replaced, inwhole or in part, by one or more pozzolanic materials. Portland cementis a hydraulic cement. Hydraulic cements harden because of a hydrationprocess; i.e., a chemical reaction between the anhydrous cement powderand water. Thus, hydraulic cements can harden underwater or whenconstantly exposed to wet weather. The chemical reaction results inhydrates that are substantially water-insoluble and so are quite durablein water. Hydraulic cement is a material that can set and hardensubmerged in water by forming insoluble products in a hydrationreaction. Other hydraulic cements include, but are not limited to,belite cement (dicalcium silicate), phosphate cements and anhydrousgypsum. However, the preferred hydraulic cement is portland cement.

Another preferred cementitious material for use with the presentinvention comprises portland cement; preferably portland cement and oneof slag cement or fly ash; and more preferably portland cement, slagcement and fly ash. Slag cement is also known as ground granulatedblast-furnace slag (GGBFS). The cementitious material preferablycomprises a reduced amount of or no portland cement and increasedamounts of recycled supplementary cementitious materials; e.g., slagcement, fly ash, energetically modified cement and/or volcanic ash. Thisresults in cementitious material and concrete that is moreenvironmentally friendly. The portland cement can also be replaced, inwhole or in part, by one or more cementitious materials other thanportland cement, slag cement or fly ash. Such other cementitious orpozzolanic materials include, but are not limited to, silica fume;metakaolin; rice hull (or rice husk) ash; ground burnt clay bricks;brick dust; bone ash; animal blood; clay; volcanic ash, energeticallymodified cement, other siliceous, aluminous or aluminosiliceousmaterials that react with calcium hydroxide in the presence of water;hydroxide-containing compounds, such as sodium hydroxide, magnesiumhydroxide, or any other compound having reactive hydrogen groups, otherhydraulic cements, other pozzolanic materials and combinations thereof.The portland cement can also be replaced, in whole or in part, by one ormore inert or filler materials other than portland cement, slag cementor fly ash. Such other inert or filler materials include, but are notlimited to limestone powder; calcium carbonate; titanium dioxide;quartz; or other finely divided minerals that densify the hydratedcement paste.

Slag cement, also known as ground granulated blast-furnace slag (GGBFS)and fly ash are both pozzolans. Pozzolan is a siliceous or siliceous andaluminous material which, in itself, possesses little or no cementitiousvalue but which will, in finely divided form and in the presence ofwater, react chemically with calcium hydroxide at ordinary temperatureto form compounds possessing cementitious properties. Such pozzolanicmaterials include, but are not limited to, volcanic ash, silica fume;metakaolin; rice hull (or rice husk) ash; ground burnt clay bricks;brick dust; bone ash; calcined shale; calcined clay; other siliceous,aluminous or aluminosiliceous materials that react with calciumhydroxide in the presence of water; hydroxide-containing compounds, suchas sodium hydroxide, magnesium hydroxide, or any other compound havingreactive hydrogen groups. The portland cement can also be replaced, inwhole or in part, by one or more inert or filler materials other thanportland cement, slag cement or pozzolanic material. Such other inert orfiller materials include, but are not limited to limestone powder;calcium carbonate; titanium dioxide; quartz; or other finely dividedminerals that densify the hydrated cement paste. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises one or more hydraulic cements and one or more pozzolans.

The preferred cementitious material for use with a disclosed embodimentof the present invention comprises 0% to approximately 100% by weightportland cement. The range of 0% to approximately 100% by weightportland cement includes all of the intermediate percentages; such as,5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%,75%, 80%, 85%, 90% and 95%. The cementitious material of the presentinvention can also comprise 0% to approximately 90% by weight portlandcement, preferably 0% to approximately 80% by weight portland cement,preferably 0% to approximately 70% by weight portland cement, morepreferably 0% to approximately 60% by weight portland cement, mostpreferably 0% to approximately 50% by weight portland cement, especially0% to approximately 40% by weight portland cement, more especially 0% toapproximately 30% by weight portland cement, most especially 0% toapproximately 20% by weight portland cement, or 0% to approximately 10%by weight portland cement. In one disclosed embodiment, the cementitiousmaterial comprises approximately 10% to approximately 45% by weightportland cement, more preferably approximately 10% to approximately 40%by weight portland cement, most preferably approximately 10% toapproximately 35% by weight portland cement, especially approximately33⅓% by weight portland cement, most especially approximately 10% toapproximately 30% by weight portland cement. In another disclosedembodiment of the present invention, the cementitious material cancomprise approximately 5% by weight portland cement, approximately 10%by weight portland cement, approximately 15% by weight portland cement,approximately 20% by weight portland cement, approximately 25% by weightportland cement, approximately 30% by weight portland cement,approximately 35% by weight portland cement, approximately 40% by weightportland cement, approximately 45% by weight portland cement orapproximately 50% by weight portland cement or any sub-combinationthereof.

The preferred cementitious material for use in one disclosed embodimentof the present invention also comprises 0% to approximately 80% byweight of one or more pozzolans, preferably approximately 10% toapproximately 80% by weight one or more pozzolans, preferablyapproximately 10% to approximately 75% by weight one or more pozzolans,preferably approximately 10% to approximately 70% by weight one or morepozzolans, preferably approximately 10% to approximately 65% by weightone or more pozzolans, preferably approximately 10% to approximately 60%by weight one or more pozzolans, preferably approximately 10% toapproximately 55% by weight one or more pozzolans, preferablyapproximately 10% to approximately 80% by weight one or more pozzolans,preferably approximately 10% to approximately 45% by weight one or morepozzolans, more preferably approximately 10% to approximately 40% byweight one or more pozzolans, most preferably approximately 10% toapproximately 35% by weight one or more pozzolans, especiallyapproximately 33⅓% by weight one or more pozzolans. In another disclosedembodiment of the present invention, the preferred cementitious materialcomprises 0% by weight one or more pozzolans, approximately 5% by weightone or more pozzolans, approximately 10% by weight one or morepozzolans, approximately 15% by weight one or more pozzolans,approximately 20% by weight one or more pozzolans, approximately 25% byweight one or more pozzolans, approximately 30% by weight one or morepozzolans, approximately 35% by weight one or more pozzolans,approximately 40% by weight one or more pozzolans, approximately 45% byweight one or more pozzolans or approximately 80% by weight one or morepozzolans, approximately 55% by weight one or more pozzolans,approximately 60% by weight one or more pozzolans, approximately 65% byweight one or more pozzolans, approximately 70% by weight one or morepozzolans or approximately 75% by weight one or more pozzolans,approximately 80% by weight one or more pozzolans or any sub-combinationthereof. Preferably the one or more pozzolans has an average particlesize of <10 μm; more preferably 90% or more of the particles have aparticles size of <10 μm.

The preferred cementitious material for use in one disclosed embodimentof the present invention also comprises 0% to approximately 90% byweight slag cement, preferably approximately 10% to approximately 90% byweight slag cement, preferably approximately 20% to approximately 90% byweight slag cement, more preferably approximately 30% to approximately80% by weight slag cement, most preferably approximately 30% toapproximately 70% by weight slag cement, especially approximately 30% toapproximately 60% by weight slag cement, more especially approximately30% to approximately 50% by weight slag cement, most especiallyapproximately 30% to approximately 40% by weight slag cement. In anotherdisclosed embodiment the cementitious material comprises approximately33⅓% by weight slag cement. In another disclosed embodiment of thepresent invention, the cementitious material can comprise approximately5% by weight slag cement, approximately 10% by weight slag cement,approximately 15% by weight slag cement, approximately 20% by weightslag cement, approximately 25% by weight slag cement, approximately 30%by weight slag cement, approximately 35% by weight slag cement,approximately 40% by weight slag cement, approximately 45% by weightslag cement, approximately 50% by weight slag cement, approximately 55%by weight slag cement, approximately 60% by weight slag cement,approximately 65%, approximately 70% by weight slag cement,approximately 75% by weight slag cement, approximately 80% by weightslag cement, approximately 85% by weight slag cement or approximately90% by weight slag cement or any sub-combination thereof.

In one disclosed embodiment, the preferred pozzolans are fly ash orvolcanic ash. Thus, preferred cementitious material for use in onedisclosed embodiment of the present invention also comprises 0% toapproximately 80% by weight of one or more pozzolans, preferably fly ashor volcanic ash, preferably approximately 10% to approximately 80% byweight fly ash or volcanic ash, preferably approximately 10% toapproximately 75% by weight fly ash or volcanic ash, preferablyapproximately 10% to approximately 70% by weight fly ash or volcanicash, preferably approximately 10% to approximately 65% by weight fly ashor volcanic ash, preferably approximately 10% to approximately 60% byweight fly ash or volcanic ash, preferably approximately 10% toapproximately 55% by weight fly ash or volcanic ash, preferablyapproximately 10% to approximately 80% by weight fly ash or volcanicash, preferably approximately 10% to approximately 45% by weight fly ashor volcanic ash, more preferably approximately 10% to approximately 40%by weight fly ash or volcanic ash, most preferably approximately 10% toapproximately 35% by weight fly ash or volcanic ash, especiallyapproximately 33⅓% by weight fly ash or volcanic ash. In anotherdisclosed embodiment of the present invention, the preferredcementitious material comprises 0% by weight fly ash or volcanic ash,approximately 5% by weight fly ash or volcanic ash, approximately 10% byweight fly ash or volcanic ash, approximately 15% by weight fly ash orvolcanic ash, approximately 20% by weight fly ash or volcanic ash,approximately 25% by weight fly ash or volcanic ash, approximately 30%by weight fly ash or volcanic ash, approximately 35% by weight fly ashor volcanic ash, approximately 40% by weight fly ash or volcanic ash,approximately 45% by weight fly ash or volcanic ash, approximately 55%by weight fly ash or volcanic ash, approximately 60% by weight fly ashor volcanic ash, approximately 65% by weight fly ash or volcanic ash,approximately 70% by weight fly ash or volcanic ash, approximately 75%by weight fly ash or volcanic ash, approximately 80% by weight fly ashor volcanic ash or any sub-combination thereof. Preferably the fly ashor volcanic ash has an average particle size of <10 μm; more preferably90% or more of the particles have a particles size of <10 μm.

The cementitious material for use in one disclosed embodiment of thepresent invention can optionally include 0.1% to approximately 20% byweight Wollastonite, preferably 0.1% to approximately 10% by weightWollastonite. Wollastonite is a calcium inosilicate mineral (CaSiO₃)that may contain small amounts of iron, magnesium, and manganesesubstituted for calcium. In addition the cementitious material canoptionally include 0.1-35% calcium oxide (quick lime), calcium hydroxide(hydrated lime), calcium carbonate or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups ormixtures or combinations thereof.

The cementitious material for use in one disclosed embodiment of thepresent invention can also optionally include inert fillers, such aslimestone powder; calcium carbonate; titanium dioxide; quartz; or otherfinely divided minerals that densify the hydrated cement paste.Specifically, inert fillers optionally can be used in the cementitiousmaterial of the present invention in amounts of 0% to approximately 40%by weight; preferably, approximately 1% to approximately 30% by weight.In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 100% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,approximately 5% to approximately 80% by weight one or more pozzolansand 0% to approximately 40% by weight inert filler. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 100% by weight portlandcement; approximately 5% to approximately 80% by weight one or morepozzolans; and 1% to approximately 40% by weight inert filler.

In one disclosed embodiment, the preferred cementitious material for usewith the present invention comprises approximately equal parts by weightof portland cement, slag cement and one or more pozzolans; i.e.,approximately 33⅓% by weight portland cement, approximately 33⅓% byweight slag cement and approximately 33⅓% by weight one or morepozzolans. In another disclosed embodiment, a preferred cementitiousmaterial for use with the present invention has a weight ratio ofportland cement to slag cement to one or more pozzolans of 1:1:1. Inanother disclosed embodiment, the preferred cementitious material foruse with the present invention has a weight ratio of portland cement toslag cement to one or more pozzolans of approximately0.85-1.15:0.85-1.15:0.85-1.15, preferably approximately0.9-1.1:0.9-1.1:0.9-1.1, more preferably approximately0.95-1.05:0.95-1.05:0.95-1.05.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 80% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 60% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 50% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 45% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 40% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 35% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 100% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 80% by weight portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash. In another disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 70% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises 0% to approximately 60% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 50% by weight portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash. In another disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 45% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises 0% to approximately 40% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 35% by weight portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 100%by weight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 90% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 80% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 70% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 60% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 90%by weight portland cement; approximately 10% to approximately 90% byweight slag cement; 0% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash; 0% to 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inone disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 80% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 0% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 70% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 0% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 60% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 0% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 0% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises less than 50% by weight portland cement;approximately 10% to approximately 90% by weight slag cement;approximately 10% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 45% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; approximately 10% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash; 0% to approximately10% by weight Wollastonite; and 0% to approximately 25% by weightcalcium oxide, calcium hydroxide, or latex or polymer admixtures, eithermineral or synthetic, that have reactive hydroxyl groups, or mixturesthereof. In another disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 35% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; approximately 10% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to approximately 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, or latexor polymer admixtures, either mineral or synthetic, that have reactivehydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises at least one of approximately 10% toapproximately 100% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In one disclosed embodiment, thecementitious material for use with the present invention comprises atleast one of approximately 10% to approximately 80% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises at least one of approximately 10% toapproximately 70% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to approximately 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, or latexor polymer admixtures, either mineral or synthetic, that have reactivehydroxyl groups, or mixtures thereof. In another disclosed embodiment,the cementitious material for use with the present invention comprisesat least one of approximately 10% to approximately 60% by weightportland cement, approximately 10% to approximately 90% by weight slagcement or approximately 5% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash; 0% to approximately 10% byweight Wollastonite; and 0% to approximately 25% by weight calciumoxide, calcium hydroxide, or latex or polymer admixtures, either mineralor synthetic, that have reactive hydroxyl groups, or mixtures thereof.In another disclosed embodiment, the cementitious material for use withthe present invention comprises at least one of approximately 10% toapproximately 50% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to approximately 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, or latexor polymer admixtures, either mineral or synthetic, that have reactivehydroxyl groups, or mixtures thereof. In another disclosed embodiment,the cementitious material for use with the present invention comprisesless than 50% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; approximately 10% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to approximately 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, or latexor polymer admixtures, either mineral or synthetic, that have reactivehydroxyl groups, or mixtures thereof. In another disclosed embodiment,the cementitious material for use with the present invention comprisesat least one of approximately 10% to approximately 45% by weightportland cement, approximately 10% to approximately 90% by weight slagcement or approximately 10% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash; 0% to approximately 10% byweight Wollastonite; and 0% to approximately 25% by weight calciumoxide, calcium hydroxide, or latex or polymer admixtures, either mineralor synthetic, that have reactive hydroxyl groups, or mixtures thereof.In another disclosed embodiment, the cementitious material for use withthe present invention comprises at least one of approximately 10% toapproximately 40% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement or approximately 10% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; 0% to approximately 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, or latexor polymer admixtures, either mineral or synthetic, that have reactivehydroxyl groups, or mixtures thereof. In another disclosed embodiment,the cementitious material for use with the present invention comprisesat least one of approximately 10% to approximately 35% by weightportland cement, approximately 10% to approximately 90% by weight slagcement or approximately 10% to approximately 80% by weight one or morepozzolans preferably fly ash or volcanic ash; 0% to approximately 10% byweight Wollastonite; and 0% to approximately 25% by weight calciumoxide, calcium hydroxide, or latex or polymer admixtures, either mineralor synthetic, that have reactive hydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 90%by weight portland cement; at least one of approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight one or more pozzolans preferably fly ash orvolcanic ash; and 0.1% to 10% by weight Wollastonite. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 80% by weight portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 60% by weight portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 50% by weight portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight one ormore pozzolans preferably fly ash or volcanic ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; and 0.1% to approximately 10% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 45% by weight portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; and 0.1% to approximately 10% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 40% by weight portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; and 0.1% to approximately 10% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 35% by weight portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight one or more pozzolanspreferably fly ash or volcanic ash; and 0.1% to approximately 10% byweight Wollastonite.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weightvolcanic ash. In one disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 80% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight volcanic ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 60% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weightvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 50% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight volcanic ash. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 45% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight volcanic ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weightvolcanic ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 35% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight volcanic ash.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, approximately 5% to approximately 80% by weight volcanicash and approximately 1% to approximately 25% by weight lime. In onedisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 80% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 70% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 60% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 50% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises less than 50% by weight portland cement,approximately 10% to approximately 90% by weight slag cement,approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 45% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 40% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 35% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 80% by weight volcanic ash andapproximately 1% to approximately 25% by weight lime.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 30% by weight silicafume. In one disclosed embodiment, the cementitious material for usewith the present invention comprises approximately 10% to approximately80% by weight portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 30% by weightsilica fume. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 70% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 30% by weight silica fume. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 60% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 30% by weight silica fume. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 30% by weight silicafume. In another disclosed embodiment, the cementitious material for usewith the present invention comprises less than 50% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 30% by weight silica fume. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 45% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 30% by weight silicafume. In another disclosed embodiment, the cementitious material for usewith the present invention comprises approximately 10% to approximately40% by weight portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 30% by weightsilica fume. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 35% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 30% by weight silica fume. In one disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 90% by weight portland cement, 0% toapproximately 90% by weight slag cement, and approximately 1% toapproximately 40% by weight silica fume.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 40% by weight silicafume. In one disclosed embodiment, the cementitious material for usewith the present invention comprises approximately 10% to approximately80% by weight portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 40% by weightsilica fume. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 70% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 40% by weight silica fume. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 60% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 40% by weight silica fume. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 40% by weight silicafume. In another disclosed embodiment, the cementitious material for usewith the present invention comprises less than 50% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 40% by weight silica fume. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 45% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 40% by weight silicafume. In another disclosed embodiment, the cementitious material for usewith the present invention comprises approximately 10% to approximately40% by weight portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 40% by weightsilica fume. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 35% by weight portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 40% by weight silica fume. In one disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 90% by weight portland cement, 0% toapproximately 90% by weight slag cement, and approximately 1% toapproximately 40% by weight silica fume.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, approximately 5% to approximately 40% by weight silica fumeand approximately 1% to approximately 25% by weight lime. In onedisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 80% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 70% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 60% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 50% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises less than 50% by weight portland cement,approximately 10% to approximately 90% by weight slag cement,approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 45% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 40% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 35% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, approximately 5% to approximately 40% by weight silica fume andapproximately 1% to approximately 25% by weight lime. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 90% by weight portlandcement, 0% to approximately 90% by weight slag cement, approximately 1%to approximately 40% by weight silica fume and approximately 1% toapproximately 25% by weight lime.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 80% by weight portlandcement, 0% to approximately 80% by weight slag cement, and approximately20% to approximately 90% by weight fly ash.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 80% by weight portlandcement, 0% to approximately 80% by weight slag cement, and approximately20% to approximately 90% by weight volcanic ash.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 80% by weight portlandcement, 0% to approximately 80% by weight slag cement, and approximately20% to approximately 90% by weight silica fume.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 95% byweight one or more pozzolans and approximately 1% to approximately 25%by weight calcium hydroxide.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 75% byweight one or more pozzolans and approximately 1% to approximately 25%by weight calcium hydroxide.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 95% byweight one or more pozzolans and approximately 1% to approximately 25%by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 75% byweight one or more pozzolans and approximately 1% to approximately 25%by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 80% by weight portlandcement, 0% to approximately 80% by weight slag cement, and approximately5% to approximately 40% by weight silica fume.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 95% byweight one or more pozzolans and approximately 1% to approximately 25%by weight lime.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 75% byweight one or more pozzolans and approximately 1% to approximately 25%by weight lime.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 5% to approximately 95% byweight one or more pozzolans and approximately 1% to approximately 25%by weight of a compound that produces calcium hydroxide in the presenceof water such that the calcium hydroxide reacts with the one or morepozzolans to form a cementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 80%by weight portland cement and the remaining cementitious materialcomprising one or more supplementary cementitious materials selectedfrom slag cement and fly ash. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 70% by weight portland cement and theremaining cementitious material comprising one or more supplementarycementitious materials selected from slag cement and fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 60% by weightportland cement and the remaining cementitious material comprising oneor more supplementary cementitious materials selected from slag cementand fly ash. In another disclosed embodiment, the cementitious materialfor use with the present invention comprises approximately 10% toapproximately 50% by weight portland cement and the remainingcementitious material comprising one or more supplementary cementitiousmaterials selected from slag cement and fly ash.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 80%by weight portland cement and the remaining cementitious materialcomprising one or more supplementary cementitious materials selectedfrom slag cement, fly ash, silica fume, rice husk ash, metakaolin, andother siliceous, aluminous or aluminosiliceous materials that react withcalcium hydroxide in the presence of water. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight portlandcement and the remaining cementitious material comprising one or moresupplementary cementitious materials selected from slag cement, fly ash,silica fume, rice husk ash, metakaolin, and other siliceous, aluminousor aluminosiliceous materials that react with calcium hydroxide in thepresence of water. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 60% by weight portland cement and the remainingcementitious material comprising one or more supplementary cementitiousmaterials selected from slag cement, fly ash, silica fume, rice huskash, metakaolin, and other siliceous, aluminous or aluminosiliceousmaterials that react with calcium hydroxide in the presence of water. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement and the remaining cementitious materialcomprising one or more supplementary cementitious materials selectedfrom slag cement, fly ash, silica fume, rice husk ash, metakaolin, andother siliceous, aluminous or aluminosiliceous materials that react withcalcium hydroxide in the presence of water.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 80%by weight portland cement and the remaining cementitious materialcomprising one or more pozzolanic materials. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight portlandcement and the remaining cementitious material comprising one or morepozzolanic materials. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 60% by weight portland cement and the remainingcementitious material comprising one or more pozzolanic materials. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight portland cement and the remaining cementitious materialcomprising one or more pozzolanic materials. In another disclosedembodiment, the foregoing cementitious materials further compriseapproximately 0.1% to approximately 10% by weight Wollastonite.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more pozzolans and a sufficientamount of calcium hydroxide, or a compound that produces calciumhydroxide in the presence of water such that the calcium hydroxidereacts with the one or more pozzolans to form a cementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more hydraulic cements and one ormore pozzolans, wherein the one or more hydraulic cements are in anamount sufficient to produces calcium hydroxide in the presence of watersufficient to react with the one or more pozzolans to form asupplementary cementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more hydraulic cements andvolcanic ash, wherein the one or more hydraulic cements are in an amountsufficient to produces calcium hydroxide in the presence of watersufficient to react with the volcanic ash to form a supplementarycementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more hydraulic cements and ricehusk ash, wherein the one or more hydraulic cements are in an amountsufficient to produces calcium hydroxide in the presence of watersufficient to react with the rice husk ash to form a supplementarycementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more hydraulic cements andmetakaolin, wherein the one or more hydraulic cements are in an amountsufficient to produces calcium hydroxide in the presence of watersufficient to react with the metakaolin to form a supplementarycementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises one or more hydraulic cements and silicafume, wherein the one or more hydraulic cements are in an amountsufficient to produces calcium hydroxide in the presence of watersufficient to react with the silica fume to form a supplementarycementitious material.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises portland cement and one or morepozzolans, wherein the portland cement is in an amount sufficient toproduces calcium hydroxide in the presence of water sufficient to reactwith the one or more pozzolans to form a supplementary cementitiousmaterial.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises portland cement, slag cement and one ormore pozzolans, wherein the portland cement and slag cement are in anamounts sufficient to produce calcium hydroxide in the presence of watersufficient to react with the one or more pozzolans to form asupplementary cementitious material.

The portland cement, slag cement and/or one or more pozzolans can becombined physically or mechanically in any suitable manner and is not acritical feature. For example, the portland cement, slag cement and/orone or more pozzolans can be mixed together to form a uniform blend ofdry material prior to combining with the aggregate and water. Or, theportland cement, slag cement and/or one or more pozzolans can be addedseparately to a conventional concrete mixer, such as the transit mixerof a ready-mix concrete truck, at a batch plant. The water and aggregatecan be added to the mixer before the cementitious material, however, itis preferable to add the cementitious material first, the water second,the aggregate third and any makeup water last.

Chemical admixtures can also be used with the preferred concrete for usewith the present invention. Such chemical admixtures include, but arenot limited to, accelerators, retarders, air entrainments, plasticizers,superplasticizers, coloring pigments, corrosion inhibitors, bondingagents and pumping aid. Although chemical admixtures can be used withthe concrete of the present invention, it is believed that chemicaladmixtures are not necessary.

Mineral admixtures can also be used with the concrete of the presentinvention. Although mineral admixtures can be used with the concrete ofthe present invention, it is believed that mineral admixtures are notnecessary. However, in some embodiments it may be desirable to include awater reducing admixture, such as a superplasticizer.

The concrete mix cured in an insulated concrete slip form in accordancewith the present invention, produces concrete with superior earlystrength and ultimate strength properties compared to the same concretemix cured in a conventional form without the use of any chemicaladditives to accelerate or otherwise alter the curing process. Thus, inone disclosed embodiment of the present invention, the preferredcementitious material comprises at least two of portland cement, slagcement and one or more pozzolans in amounts such that at three to sevendays the concrete mix cured in accordance with the present invention hasa compressive strength at least 50% greater than the same concrete mixwould have after the same amount of time in a conventional (i.e.,non-insulated) concrete form under ambient conditions. In anotherdisclosed embodiment, the preferred concrete mix cured in accordancewith the present invention has a compressive strength at least 25%, atleast 50%, at least 75%, at least 100%, at least 150%, at least 200%, atleast 250% or at least 300% greater than the same concrete mix wouldhave after the same amount of time in a conventional (i.e.,non-insulated) concrete form under the same conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement, slag cement and one ormore pozzolans in amounts such that at three to seven days the concretemix cured in accordance with the present invention has a compressivestrength at least 25% or at least 50% greater than the same concrete mixwould have after three days in a conventional concrete form underambient conditions. In another disclosed embodiment the preferredconcrete mix cured in accordance with the present invention has acompressive strength at least 25%, at least 50%, at least 75%, at least100%, at least 150%, at least 200%, at least 250% or at least 300%greater than the same concrete mix would have after the same amount oftime in a conventional (i.e., non-insulated) concrete form under thesame conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and slag cement inamounts such that at three to seven days the concrete mix cured inaccordance with the present invention has a compressive strength atleast 25% or at least 50% greater than the same concrete mix would haveafter the same time period in a conventional concrete form under ambientconditions. In another disclosed embodiment, the preferred concrete mixcured in accordance with the present invention has a compressivestrength at least 100%, at least 150%, at least 200%, at least 250% orat least 300% greater than the same concrete mix would have after thesame amount of time in a conventional (i.e., non-insulated) concreteform under the same conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and one or morepozzolans in amounts such that at three to seven days the concrete mixcured in accordance with the present invention has a compressivestrength at least 25% or at least 50% greater than the same concrete mixwould have after the same time period in a conventional concrete formunder ambient conditions. In another disclosed embodiment the preferredconcrete mix cured in accordance with the present invention has acompressive strength at least 100%, at least 150%, at least 200%, atleast 250% or at least 300% greater than the same concrete mix wouldhave after the same amount of time in a conventional (i.e.,non-insulated) concrete form under the same conditions.

The present invention can also be used to accelerate the curing of highperformance concrete mixes and ultra high performance concrete mixes.High performance concrete has a compressive strength of approximately10,000 psi to approximately 20,000 psi. Ultra high performance concretehas a compressive strength greater than approximately 20,000 psi.

The present invention can be used to form any type of concrete structureor object, either cast in place or precast. The present invention can beused to form footings, retaining walls, exterior walls of buildings,load-bearing interior walls, columns, piers, parking deck slabs,elevated slabs, roofs, bridges, or any other structures or objects.Also, the present invention can be used to form precast structures orobjects, tilt-up concrete panels for exterior walls of buildings,load-bearing interior walls, columns, piers, parking deck slabs,elevated slab, roofs and other similar precast structures and objects.Additionally, the present invention can be used to form precaststructures including, but not limited to, walls, floors, decking, beams,railings, pipes, vaults, underwater infrastructure, modular pavingproducts, retaining walls, storm water management products, culverts,bridge systems, railroad ties, traffic barriers, tunnel segments, lightpole beams, light pole bases, transformer pads, and the like.

It should be understood, of course, that the foregoing relates only tocertain disclosed embodiments of the present invention and that numerousmodifications or alterations may be made therein without departing fromthe spirit and scope of the invention.

What is claimed is:
 1. A concrete forming system comprising: a firstmovable concrete form spaced from a second movable concrete form therebydefining a concrete receiving space therebetween; each of the first andsecond movable concrete forms comprising a sandwich panel attached to areinforcing frame structure; each sandwich panel comprising; a firstrigid panel member; a second rigid panel member; an intermediate layerof foam insulating material disposed between the first and second rigidpanel members; and an insulating blanket adjacent each of the first andsecond movable concrete forms.
 2. The concrete forming system of claim1, wherein the sandwich panel defines a plane and wherein the insulatingblanket is substantially in the plane defined by the sandwich panel. 3.The concrete forming system of claim 1, wherein the intermediate layerof foam insulating material has an R-value of greater than 1.5.
 4. Theconcrete forming system of claim 1, wherein the intermediate layer offoam insulating material has an R-value of greater than
 4. 5. Theconcrete forming system of claim 1, wherein the intermediate layer offoam insulating material has an R-value of greater than
 8. 6. Theconcrete forming system of claim 1, wherein the insulating blanket hasan R-value of greater than 1.5.
 7. The concrete forming system of claim1, wherein the insulating blanket has an R-value of greater than
 4. 8.The concrete forming system of claim 1, wherein the insulating blankethas an R-value of greater than
 8. 9. The concrete forming system ofclaim 1 further comprising an electric heating element in thermalcontact with the first rigid panel member.
 10. The concrete formingsystem of claim 1 further comprising an electric heating element in theinsulating blanket.
 11. The concrete forming system of claim 1 whereinthe reinforcing frame structure comprises a plurality of bracing membersoriented transversely with respect to the sandwich panel, the frameproviding sufficient reinforcement to the sandwich panel such that thesandwich panel withstands the hydrostatic pressure of plastic concretecontacting the sandwich panel.
 12. A concrete forming system comprising:a first movable concrete form spaced from a second movable concrete formthereby defining a concrete receiving space therebetween; each of thefirst and second movable concrete forms comprising a sandwich panelattached to a reinforcing frame structure; each sandwich panelcomprising; a first rigid panel member; a second rigid panel member; anintermediate layer of foam insulating material disposed between thefirst and second rigid panel members; and a layer of insulating materialadjacent each of the first and second movable concrete forms.
 13. Theconcrete forming system of claim 12, wherein the intermediate layer offoam insulating material has an R-value of greater than 1.5.
 14. Theconcrete forming system of claim 12, wherein the intermediate layer offoam insulating material has an R-value of greater than
 4. 15. Theconcrete forming system of claim 12, wherein the intermediate layer offoam insulating material has an R-value of greater than
 8. 16. Theconcrete forming system of claim 12, wherein the layer of insulatingmaterial has an R-value of greater than 1.5.
 17. The concrete formingsystem of claim 12, wherein the layer of insulating material has anR-value of greater than
 4. 18. The concrete forming system of claim 12,wherein the layer of insulating material has an R-value of greater than8.